Organic and Inorganic Light Active Devices and Methods for Making the Same

ABSTRACT

A method for making a light active device, including providing a mixture of light active material and a monomer in a first region and a second region. The light active material includes a plurality of electro-statically active microcapsules each comprising OLED material encapsulated within a polymer shell. Chains of the electro-statically active microcapsules are formed in the first region. The monomer is cured to form a polymer in the first region and in the second region to lock the chains of the electro-statically active microcapsules in the first region.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation application of U.S. Ser. No. 10/716,794, filedNov. 19, 2003, which is a utility application of provisional applicationSer. No. 60/469,667, filed May 12, 2003. U.S. Ser. No. 10/716,794 is acontinuation-in-part of U.S. Utility patent application Ser. No.10/375,161, filed Feb. 26, 2003, which is a continuation-in-part of U.S.Utility patent application Ser. No. 10/321,161, filed Dec. 17, 2002which is the U.S. Utility patent application of a Provisional PatentApplication Ser. No. 60/427,333, filed Nov. 19, 2002. This applicationis related to co-pending patent application Ser. No. 11/453,627 filedJun. 14, 2006; co-pending U.S. patent application Ser. No. 10/234,301filed Sep. 4, 2002; and U.S. Pat. No. 7,161,590, dated Jan. 9, 2007. Thesubject matter of the above mentioned patent documents is incorporatedby reference herein in their entirety.

BACKGROUND OF THE INVENTION

The present invention pertains to organic and inorganic light activedevices, and hybrids thereof, and methods of making the same. Moreparticularly, the present invention pertains to devices and methods forfabricating light active devices that can be used for applications suchas general lighting, display backlighting, video displays, Internetappliances, electronic books, digital newspapers and maps, stereoscopicvision aides, head mounted displays, advanced vehicle windshields, solarcells, cameras and photodetectors. A multi-color single layer lightactive device is disclosed. Also disclosed is a sequential burst drivingscheme for a multi-color single layer display. Further disclosed aremethods for making light active material particulate, as well as anorganic light active fiber. Still further disclosed are methods forfabricating injection and other plastic molded organic light activedevices. Further still there are disclosed compositions for light activematerial.

A polymer is made up of organic molecules bonded together. For a polymerto be electrically conductive it must act like a metal with theelectrons in the bonds mobile and not bound to the atoms making up theorganic molecules. A conductive polymer must have alternate single anddouble bonds, termed conjugated double bonds.

Polyacetylene is a simple conjugated polymer. It is made by thepolymerization of acetylene. In the early 1970's, a researcher namedShirakawa was studying the polymerization of acetylene. When too muchcatalyst was added, the mixture seemed to have a metallic appearance.But unlike metals, the resulting polyacetylene film was not anelectrical conductor. In the mid-1970's this material was reacted withiodine vapor. The result was an extreme increase in the conductivity ofthe polymer film, and ultimately resulted in a Nobel Prize in Chemistryfor the researchers who discovered it.

Although polyacetylene can be made as conductive as some metals, itsconductivity drops rapidly in contact with air. This has led to thedevelopment of more stable, conjugated polymers, for example,polypyrrol, polyaniline and polytiophene.

There is now intensive development working with conjugated polymers intheir un-doped, semiconductive state. It was found that some conjugatedpolymers exhibit electroluminescence when a voltage is applied. Further,the absorption of light by the semiconductive polymer results inpositive and negative charges that produce an electric current. Thus,conjugated polymers can be used to make solar cells and light detectors.

Organic light active material (“OLAM™”) makes use of the relativelyrecent discovery that polymers can be made to be conductors. Organiclight emitting diodes (“OLED”) convert electrical energy into light,behaving as a forward biased pn junction. OLAMs can be light emitters orlight detectors, depending on the material composition and the devicestructure. For the purpose of this disclosure, the term OLAM and OLEDcan be interchanged. In its basic form, an OLED is comprised of a layerof hole transport material upon which is formed a layer of electrontransport material. The interface between these layers forms aheterojunction. These layers are disposed between two electrodes, withthe hole transport layer being adjacent to an anode electrode and theelectron transport layer being adjacent to a cathode electrode. Uponapplication of a voltage to the electrodes, electrons and holes areinjected from the cathode electrode and the anode electrode. Theelectron and hole carriers recombine at the heterojunction formingexcitons and emitting light.

The basic structure of an OLED display is similar to a conventional LCD,where the reactive material (in the LCD case, a liquid crystal, in theOLED case, a conjugated polymer) is sandwiched between electrodes. Whenan electric field is applied by the electrodes, the OLED material isbrought into an excited energy state, this energy state drops down bythe emission of photons, packets of light. Thus, each pixel of the OLEDdisplay can be controlled to emit light as needed to create a displayedimage.

OLEDs used as pixels in flat panel displays have significant advantagesover backlit active-matrix LCD displays. OLED displays have a greaterviewing angle, lighter weight, and quicker response. Since only the partof the display that is actually lit up consumes power, OLEDs use lesspower. Based on these advantages, OLEDs have been proposed for a widerange of display applications including computer monitors, televisions,magnified microdisplays, wearable, head-mounted computers, digitalcameras, personal digital assistants, smart pagers, virtual realitygames, and mobile phones as well as medical, automotive, and otherindustrial applications. The unstoppable march of technology oftenchanges the way we see the world. Now, the way we see the world is aboutto be transformed by a new kind of display technology. The discovery oforganic light emitting polymer technology (OLED) is creating a new classof flat panel displays that are set to change not only the nature of thedisplay products that are all around us, but how they are manufacturedas well. Articulated Technologies, has developed an advanced full colorOLED display fabrication method. One of the biggest challenges to theOLED display industry is from contamination by water and oxygen. Thematerials involved in small molecule and polymer OLEDs are vulnerable tocontamination by oxygen and water vapor, which can trigger earlyfailure. This issue is exacerbated when non-glass substrates are used.Since OLEDs offer the promise of a bendable display, attempts have beenmade to use plastic substrates in place of glass. Elaborate barriermechanisms have been proposed to encapsulate the OLED device and protectthe organic stack from the ingress of water and oxygen. Also, desiccantshave been used to reduce the contamination. Neither of these solutionsis adequate, adding to the cost and complexity of forming an OLEDdevice. In the end, the problems caused by the ingress of water andoxygen to the organic stack continue to pose serious technical issues.FIG. 111 illustrates a prior art OLED device. Very basically, an OLED iscomprised of extremely thin layers of organic material forming anorganic stack. These layers are sandwiched between an anode electrodeand a cathode electrode. When voltage is applied to the electrodes,holes and electrons are injected into the organic stack. The holes andelectrons combine to form unstable excitons. When the excitons decay,light is emitted.

The current state of every available OLED fabrication technologyrequires the formation of very thin films of organic light emittingmaterial. These thin films are formed by a variety of known techniquessuch as vacuum deposition, screen printing, transfer printing and spincoating, or by the re-purposing of existing technology such as ink jetprinting. In any case, the current state of the art has at its core theformation of very thin film layers of organic material. These thin filmsmust be deposited uniformly and precisely. Such thin layers of organicmaterial are susceptible to major problems, such as loss of filmintegrity, particularly when applied to a flexible substrate. FIG. 112illustrates a prior art OLED device wherein a dust spec creates anelectrical short between the electrodes. The extreme thinness of thelayers of organic material between conductors also results in electricalshorts easily forming due to even very small specks of dust or othercontaminants. Because of this limitation, costly cleanroom facilitiesmust be built and maintained using the conventional OLED thin filmfabrication techniques. Currently, inkjet printing has gained ground asa promising fabrication method for making OLED displays. However, thereare some serious disadvantages to the adapting of inkjet printing toOLED display fabrication. Inkjet printing does not adequately overcomethe problem of material degradation by oxygen and water vapor. FIG. 113illustrates a prior art OLED device wherein the thin organic film stackis degraded by the ingress of oxygen and/or water. Elaborate andexpensive materials and fabrication processes are still required toprovide adequate encapsulation to protect and preserve the thin organicfilms. It is difficult to align display pixel-sized electrodes andinkjet printed OLED material with the accuracy needed to effect a highresolution display.

Besides attractive picture quality, an OLED display device consumes lesspower than liquid crystal display technologies because it emits its ownlight and does not need backlighting. OLED displays are thin,lightweight, and may be able to be manufactured on flexible materialssuch as plastic.

Unlike liquid-crystal displays, OLEDs emit light that can be viewed fromany angle, similar to a television screen. As compared to LCDs, OLEDsare expected to be much less expensive to manufacture, use less power tooperate, emit brighter and sharper images, and “switch” images faster,meaning that videos or animation run more smoothly.

Recently, an effort has been made to create equipment and provideservices for manufacturing OLED screens. The potential OLED displaymarket includes a wide range of electronic products such as mobilephones, personal digital assistants, digital cameras, camcorders,micro-displays, personal computers, Internet appliances and otherconsumer and military products.

There is still a need, for example, for a thin, lightweight, flexible,bright, wireless display. Such a device would be self-powered, robust,include a built-in user-input mechanism, and ideally functional as amultipurpose display device for Internet, entertainment, computer, andcommunication use. The discovery of the OLED phenomenon puts this goalwithin sight.

However, there are still some technical hurdles that remain to be solvedbefore OLED displays will realize their commercial potential. OLED'slight emitting materials do not have a long service life. Presently,optimum performance in commercially viable volume production isachievable only for small screens, around 3.5 inches square or less.Storage lifetimes of at least 5 years are typically required by mostconsumer and business products, and operating lifetimes of >20,000 hoursare relevant for most applications.

Organic light emitting diode technology offers the prospect of flexibledisplays on plastic substrates and roll-to-roll manufacturing processes.One of the biggest challenges to the OLED display industry is fromcontamination by water and oxygen. The materials involved in smallmolecule and polymer OLEDs are vulnerable to contamination by oxygen andwater vapor, which can trigger early failure. As an example of an OLEDdevice, U.S. Pat. No. 5,247,190 issued to Friend et al., teaches anelectroluminescent device comprising a semiconductor layer in the formof a thin dense polymer film comprising at least one conjugated polymersandwiched between two contact layers that inject holes and electronsinto the thin polymer film. The injected holes and electrons result inthe emission of light from the thin polymer film.

There has been recent activity in developing thin, flexible displaysthat utilize pixels of electro-luminescent materials, such as OLEDs.Such displays do not require any back lighting since each pixel elementgenerates its own light. Typically, the organic materials are depositedby solution processing such as spin-coating, by vacuum deposition orevaporation. As examples, U.S. Pat. No. 6,395,328, issued to May,teaches an organic light emitting color display wherein a multi-colordevice is formed by depositing and patterning thin layers of lightemissive material. U.S. Pat. No. 5,965,979, issued to Friend, et al.,teaches a method of making a light emitting device by laminating twoself-supporting components, at least one of which has a thin layer oflight emitting layer. U.S. Pat. No. 6,087,196, issued to Strum, et al.,teaches a fabrication method for forming organic semiconductor devicesusing ink jet printing for forming thin layers of organic light emittingmaterial. U.S. Pat. No. 6,416,885 B1, issued to Towns et al., teaches anelectro-luminescent device wherein a conductive polymer thin layer isdisposed between an organic light emitting thin layer and acharge-injecting thin layer that resists lateral spreading of chargecarriers to improve the display characteristics. U.S. Pat. No. 6,420,200B1, issued to Yamazaki et al., teaches a method of manufacturing anelectro-optical device using a relief printing or screen printing methodfor printing thin layers of electro-optical material. U.S. Pat. No.6,402,579 B1, issued to Pichler et al., teaches an organiclight-emitting device in which a multi-layer structure is formed by DCmagnetron sputtering to form multiple thin layers of organic lightemitting material.

Electrophoretic displays are another type of display that has recentlybeen the subject of research. U.S. Pat. No. 6,422,687 B1, issued toJacobson, teaches an electronically addressable microencapsulated inkand display. In accordance with the teachings of this reference,microcapsules are formed with a reflective side and a light absorbingside. The microcapsules act as pixels that can be flipped between thetwo states, and then keep that state without any additional power. Inaccordance with the teaching of this reference, a reflective display isproduced where the pixels reflect or absorb ambient light depending onthe orientation of the microcapsules.

Other examples of OLED-type displays include U.S. Pat. No. 5,858,561,issued to Epstein et al. This reference teaches a light emitting bipolardevice consisting of a thin layer of organic light emitting materialsandwiched between two layers of insulating material. The device can beoperated with AC voltage or DC voltage. U.S. Pat. No. 6,433,355 B1,issued to Riess et al., teaches an organic light emitting device whereina thin organic film region is disposed between an anode electrode and acathode electrode, at least one of the electrodes comprises anon-degenerate wide band-gap semiconductor to improve the operatingcharacteristic of the light emitting device. U.S. Pat. No. 6,445,126 B1,issued to Arai et al., teaches an organic light emitting device whereinan organic thin layer is disposed between electrodes. An inorganicelectrode or hole injecting thin film is provided to improve efficiency,extend effective life and lower the cost of the light emitting device.

It is known to form a thin OLED layer by various methods includingvacuum deposition, evaporation or spin coating. Thin layers of holetransport material and then electron transport material are formed bythese known methods over a grid of anode electrodes. The anodeelectrodes are formed on a glass plate. A grid of cathode electrodes isthen placed adjacent to the electron transport material supported by asecond glass plate. Thus, the basic OLED organic stack is sandwichedbetween electrodes and glass plate substrates. It is generally verydifficult to form the electrodes with the precise alignment needed forforming a pixilated display. This task is made even more difficult in amulticolor display, where the OLED pixels emitting, for example, red,green and blue, are formed side-by-side to fabricate a full colordisplay. Because the OLED material and electrodes can be madetransparent, it is possible to stack the color OLED pixels on top ofeach other, allowing for a higher pixel packing density and thus thepotential for a higher resolution display. However, the electrodealignment issue still poses a problem. Typically, the well-known use ofshadow masks are employed to fabricate the pixel components. Aligningthe shadow masks is difficult, and requires extreme precision.

Currently, inkjet printing has gained ground as a promising fabricationmethod for making OLED displays. The core of this technology is verymature, and can be found in millions of computer printers around theworld. However, there are some serious disadvantages to the adapting ofinkjet printing to OLED display fabrication. It is still difficult tolay down precise layers of material using the spray heads of inkjetprinters. Inkjet printing does not adequately overcome the problem ofmaterial degradation by oxygen and water vapor. Elaborate and expensivematerials and fabrication processes are needed to provide adequateencapsulation of the display elements to prevent early degradation ofthe OLED material due to water and oxygen ingress. As an attempt tosolve this contamination problem, Vitex Systems, Sunnyvale, Calif., hasdeveloped a barrier material in which a monomer vapor is deposited on apolymer substrate, and then the monomer is polymerized. A thin layer ofaluminum oxide a few hundred angstroms thick is deposited on thepolymerized surface. This process is repeated a number of times to forman encapsulation barrier over an OLED display. This elaborateencapsulation barrier is an example of the effort taken to prevent waterand oxygen from contaminating the easily degraded OLED films that form aconventional OLED display device. Even with this elaborate encapsulationprocess, the edges of the OLED display still need to be sealed.

It is difficult to align display pixel-sized electrodes and inkjetprinted OLED material with the accuracy needed to effect a highresolution display. All of the known fabrication methods formanufacturing an OLED device require the formation and preservation ofvery thin layers of reactive organic material. These ultra thin layersare disposed between oppositely charged electrodes. Electrical shortsand the destruction of pixels result from the inclusion of evenminiscule foreign particles when forming the organic thin film layers.To limit this serious drawback, the conventional fabrication processesrequires the use of expensive clean room or vacuum manufacturingfacilities. Even with a gh clean room or vacuum chamber, the typicalOLED display device either has to use glass substrates or an elaborateencapsulation system to overcome the problems of water and oxygeningress. Accordingly there is an urgent need for an improved fabricationmethod for forming OLED devices.

There is also a need for a multi-color OLED structure whereby two ormore colors of light can be produced from a single pixel or OLED device.U.S. Pat. No. 6,117,567, issued to Andersson et al, teaches a lightemitting polymer device for obtaining voltage controlled colors based ona thin polymer film incorporating more than one electroluminescentconjugated polymer. The polymer thin film is sandwiched between twoelectrodes. Upon application of different voltages to the electrodes,different colors of light are emitted from the conjugated polymerscontained in the thin film. It is hoped that multiple color OLED filmswill somehow facilitate the formation of a full color emissive displayscreen. Typically, a full color display is obtained by forming pixelscomprised of three separately controllable subpixels. Each subpixel iscapable of controlling the emission of a wavelength of one of the threeprimary colors light, red, green and blue.

Edwin Land introduced a theory of color vision based on center/surroundretinex (see, An Alternative Technique for the Computation of theDesignator in the Retinex Theory of Color Vision,” Proceedings of theNational Academy of Science, Volume 83, pp. 3078-3080, 1986). Landdisclosed his retinex theory in “Color Vision and The Natural Image,”Proceedings of the National Academy of Science, Volume 45, pp. 115-129,1959. These retinex concepts are models for human color perception.Others have shown that a digital image can be improved utilizing thephenomenon of retinex (see, U.S. Pat. No. 5,991,456 issued to Rahman etal, the disclosure of which is incorporated by reference herein). Theinventors of the U.S. Pat. No. 5,991,456 patent used Land's retinextheory and devised a method of improving a digital image where the imageis initially represented by digital data indexed to represent positionson a display. According to the inventors of the U.S. Pat. No. 5,991,456patent, an improved digital image can then be displayed based on theadjusted intensity value for each i-th spectral band so-filtered foreach position. For color images, a novel color restoration step is addedto give the image true-to-life color that closely matches humanobservation.

Nanoparticles are used in unrelated applications, such as drug deliverydevices. Others have shown that very small polymer-based particles canbe made by a variety of methods. These drug delivery nanoparticles varyin size from 10 to 1000 nm. A drug can be dissolved, entrapped,encapsulated or attached to a nanoparticle matrix. Depending on themethod of preparation, nanoparticles, nanospheres or nanocapsules can beobtained. (see, Biodegradable Polymeric Nanoparticles as Drug DeliveryDevices, K. S., Soppimath et al., Journal of Controlled Release, 70(2001) 1-20).

Recently, researchers have demonstrated a process for making a compositematerial comprised of polymer interspersed with liquid-crystal droplets.The optical response of this material can be controlled by applying avoltage, and has been used to create photonic crystals that modulate thetransmission of light. (see, Liquid-Crystal Holograms Form PhotonicCrystals, by Graham P. Collins, Scientific American, July, 2003). Amixture of monomer molecules and liquid-crystal molecules are disposedbetween two sheets of a substrate. The substrate can be, for example,glass plated with a thin layer of conducting material. The mixture isirradiated with two or more laser beams. The laser beams are aligned andpolarized to generate a specific holographic interference pattern havingalternating dark and light areas. At the bright regions in the pattern,the monomers undergo polymerization. As the polymerization reactionprogresses, the monomer migrates from the dark regions to the brightregions, causing the liquid crystal to become concentrated in the darkregions. The end result is a solid polymer with droplets of liquidcrystal embedded in a pattern corresponding to the dark regions of theholographic interference pattern.

The current state of the OLED fabrication technology requires theformation of very thin films of organic light emitting material. Thesethin films are formed by known techniques such as vacuum deposition,screen printing, transfer printing and spin coating, or by there-purposing of existing technology such as ink jet printing. In anycase, the current state of the art has at its core the formation of verythin film layers of organic material. These thin films must also bedeposited very uniformly and precisely, which has proven extremelydifficult to do. These thin layers of organic material are susceptibleto major problems, such as shortened device lifetime due to ingress ofwater and oxygen, and delamination, particularly when applied to aflexible substrate. The extreme thinness of the layers of organicmaterial between conductors also results in electrical shorts easilyforming due to even very small specks of dust or other contaminants.Because of this limitation, costly cleanroom facilities must be builtand maintained using the conventional OLED thin film fabricationtechniques. Organic light emitting devices offer tremendous potentialdue to the inherent qualities of the organic materials, however, thecurrent state of the art fabrication methods are limiting the deliveryof this potential to the consumer.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the drawbacks ofthe prior art. It is an object of the present invention to provide amethod of fabricating a light active device by dispersing threedimensionally a semiconductor particulate within a carrier material. Theresulting structure has individual point sources of light emissiondispersed within a protective barrier material. The barrier materialprovides strength to the device and adhesion to the electrodes and/orother films and prevents contamination of the semiconductor particulate.The inventive fabrication method also allows multiple colors to beemitted from the inventive mixture between a single pair of electrodesforming a pixel or device. In an inventive display driving scheme, anarray of such pixels is driven so that bursts of color emissions occurin rapid succession resulting in the perception by the human eye of arange of colors in the visible spectrum. Thus, in accordance with thisaspect of the invention, a single emissive layer and pair of electrodescan be used to create a full color video display. The inventive OrganicLight Active Material (OLAM™) structure can also be used to detect aspectrum of colors when the device is constructed as a photodetector.

It is another object of the present invention to provide a light activefiber that has the advantages of the OLED phenomenon. The inventivelight active fiber includes an elongated hardened conductive carriermaterial. A semiconductor particulate is dispersed within the conductivecarrier material. A first contact area is provided so that onapplication of an electric field charge carriers of a first type areinjected into the semiconductor particulate through the conductivecarrier material. A second contact layer is provided so that onapplication of an electric field to the second contact layer chargecarriers of a second type are injected into the semiconductorparticulate through the conductive carrier material. The semiconductorparticulate may comprise at least one of an organic and an inorganicsemiconductor.

The conductive carrier material may comprise a binder material with oneor more characteristic controlling additives. The characteristiccontrolling additives are a particulate and/or a fluid and may include adesiccant; a conductive phase, a semiconductive phase, an insulativephase, a mechanical strength enhancing phase, an adhesive enhancingphase, a hole injecting material, an electron injecting material, a lowwork metal, a blocking material, and an emission enhancing material.

The first and the second contact may comprise a first conductive memberdisposed longitudinally within the elongated hardened conductive carriermaterial. The other of the first and the second contact may comprises asecond conductive member disposed adjacent to the first conductivemember so that at least a portion of the semiconductor particulate isdisposed between the first conductive and the second conductive member.

The first conductive member comprises a conductive material comprised ofat least one of a metal and a conductive polymer disposed in theinterior of the elongated hardened conductive carrier material; and thesecond conductive member comprises a conductive material comprised of atleast one of a metal and a conductive polymer disposed as a coating onthe exterior of the elongated hardened conductive carrier material.

In accordance with another aspect of the present invention, an injectionmoldable light active material is provided comprising: a semiconductorlight active particulate dispersed within a hardenable carrier material.The semiconductor light active particulate may include at least one ofan organic and an inorganic semiconductor. The organic light activeparticulate can include particles including at least one of holetransport material, organic emitter, and electron transport material.The organic light active particulate can include particles including apolymer blend. The polymer blend may include an organic emitter blendedwith at least one of a hole transport material, an electron transportmaterial and a blocking material. Additional organic emitters can beincluded within the polymer blend. The organic light active particulatecan comprise microcapsules including a polymer shell encapsulating aninternal phase comprised of a polymer blend.

The carrier material can be a hardenable binder material with one ormore characteristic controlling additives. The characteristiccontrolling additives may include at least one of a particulate and afluid. The characteristic controlling additives may include a desiccant,a scavenger, a conductive phase, a semiconductive phase, an insulativephase, a mechanical strength enhancing phase, an adhesive enhancingphase, a hole injecting material, an electron injecting material, a lowwork metal, a blocking material, and an emission enhancing material. Theparticulate may include at least one of an organic emitter, an inorganicemitter, hole transport material, blocker material, electron transportmaterial, and performance enhancing materials. The carrier may includeat least one of an organic emitter; an inorganic emitter, hole transportmaterial, blocker material, electron transport material, and performanceenhancing materials (e.g., the characteristic controlling additives).

In accordance with the present invention, the injection moldable lightactive material can be provided wherein the semiconductive light activeparticulate is comprised of first emitting particles for emitting anumber of photons of a first color in response to a first turn-onvoltage applied to the electrodes and emitting a different number ofphotons of the first color in response to other turn-on voltages. Thesemiconductive light active particulate may further include secondemitting particles. The second emitting particles emit a number ofphotons of a second color in response to a second turn-on voltage and adifferent number of photons of the second color in response to otherturn-on voltages. By this composition and construction, a multi-coloredlight active material is obtained.

The particulate can be composed so as to have a first end having anelectrical polarity and a second end having an opposite electricalpolarity. The particulate is alignable within the conductive carrier sothat charge carriers of a first type are more easily injected into thefirst end and charge carriers of a second type are more easily injectedinto the second end.

In accordance with another aspect of the present invention, a photonreceptive light active device is provided. A first electrode and asecond electrode are provided disposed adjacent defining a gap therebetween. A light active mixture is provided comprised of a carriermaterial and a photon receptive particulate for receiving a photon oflight and converting the photon of light into electrical energy. Thelight active mixture being disposed within the gap between the firstelectrode and the second electrode so that when light energy is receivedby the photon receptive particulate, electrical energy is produced thatcan be derived from an electrical connection with the first electrodeand the second electrode. With this composition and construction, alight-to-energy device is obtained from which a solar cell,photodetector or camera element can be made.

The photon receptive particulate may include at least one of an organicphoton receiver; an inorganic photon receiver, hole transport material,blocker material, electron transport material, and performance enhancingmaterials. The carrier can include at least one of an organic photonreceiver; an inorganic photon receiver, hole transport material, blockermaterial, electron transport material, and performance enhancingmaterials. Further, additional layers may be formed within the gapbetween the first electrode and the second electrode. These additionallayers help to define the mechanical, electrical and opticalcharacteristics of the inventive device. The additional layers mayinclude at least one of an organic photon receiver; an inorganic photonreceiver, hole transport material, blocker material, electron transportmaterial, and performance enhancing materials (e.g., the characteristiccontrolling additives).

Applicants have discovered that the ultra thin film nature of aconventional organic light active device results in many disadvantages.These disadvantages include, but are not limited to, electrical shortscaused by the inclusion of small foreign particles, cross talk amongpixels in a display array, delamination of the thin film, deteriorationof the thin film by the ingress of oxygen and water, and other seriousfailings. In accordance with the present invention, the disadvantagescaused by having an extremely small gap distance between electrodes isovercome by expanding this gap distance. Thus, in accordance with thepresent invention, an organic light active device includes a firstelectrode and a second electrode disposed adjacent to the firstelectrode. The first and second electrode define a gap there between. Anorganic emissive layer is disposed within said gap. To overcome the thinfilm issues, and to enhance the performance of the inventive device, agap expanding composition is also disposed within said gap. This gapexpanding composition is effective to increase the gap distance betweenthe top and bottom electrode.

The gap expanding composition may include at least one of an insulator,a conductor and a semiconductor. The gap expanding composition caninclude at least one additional layer formed between the first electrodeand the second electrode. The additional layers may include at least oneof an organic photon receiver; an inorganic photon receiver, holetransport material, blocker material, electron transport material,radiation emitting material and performance enhancing materials. The gapexpanding composition can include at least one of a desiccant; ascavenger, a conductive material, a semiconductive material, aninsulative material, a mechanical strength enhancing material, anadhesive enhancing material, a hole injecting material, an electroninjecting material, a low work metal, a blocking material, and anemission enhancing material.

The emissive layer can comprise an emissive particulate dispersed withina carrier.

The emissive particulate has a first end having an electrical polarityand a second end having an opposite electrical polarity. The particulatecan be alignable within the conductive carrier so that charge carriersof a first type are more easily injected into the first end and chargecarriers of a second type are more easily injected into the second end.

The emissive layer may be an organic thin film layer. The gap expandingcomposition can include a conductive, insulative and/or semiconductivematerial composition that reduces the emission efficiency of theemissive layer while increasing the light active device effectiveness byexpanding the gap distance between the electrodes. With a carefulselection of constituent components, this reduction in efficiency can belimited so that the benefits of expanding the gap distance between theelectrodes can be obtained without too much cost in device efficiency.

In accordance with another aspect of the present invention, a lightactive device includes a semiconductor particulate dispersed within acarrier material. A first contact layer is provided so that onapplication of an electric field, charge carriers having a polarity areinjected into the semiconductor particulate through the conductivecarrier material. A second contact layer is provided so that onapplication of the electric field to the second contact layer, chargecarriers having an opposite polarity are injected into the semiconductorparticulate through the conductive carrier material. The semiconductorparticulate comprises at least one of an organic and an inorganicsemiconductor. The semiconductor particulate may comprise an organiclight active particulate that includes at least one conjugated polymer.When an electric field is applied between the first and second contactlayers to the semiconductor particulate through the conductive carriermaterial, the second contact layer becomes positive relative to thefirst contact layer and charge carriers of opposite polarity areinjected into the semiconductor particulate. The opposite polaritycharge carriers combine to form in the conjugated polymer charge carrierpairs which decay radiatively so that radiation is emitted from theconjugated polymer. In this case, the inventive light active device actsas a light emitting diode.

The present invention can be used with small molecule OLED materials aswell as large molecule OLED materials. It is very difficult orimpossible to dissolve small molecule OLED materials in a liquid and sothe current state-of-the-art requires such material to be vacuumdeposited as a very thin film to form an OLED device, using for example,a process similar to the fabrication of a computer microprocessor chip.But because the displays are typically much larger than chips, thatfabrication process is prohibitively expensive for forming a largedisplay. However, in accordance with the present invention, particulateof the small molecule OLED material can be mixed with the carriermaterial and disposed within the gap between the electrodes. Theparticulate can include other materials, such as organic and inorganiccharacteristic enhancing materials to control the electrical, chemical,optical, mechanical and magnetic properties of the light active device.

The organic light active particulate may include particles comprisedfrom a polymer blend. The polymer blend including at least one organicemitter blended with at least one of a hole transport material, ablocking material, and an electron transport material. The organic lightactive particulate may include microcapsules having a polymer shellencapsulating an internal phase. The internal phase and/or the shell canbe comprised of a polymer blend including an organic emitter blendedwith at least one of a hole transport material, a blocking material, andan electron transport material.

To form a display device, the first contact layer and the second contactlayer can be arranged to form an array of pixel electrodes. Each pixelincludes a portion of the semiconductor particulate dispersed within theconductive carrier material. Each pixel is selectively addressable byapplying a driving voltage to the appropriate first contact electrodeand the second contact electrode.

Another aspect of the present invention provides a voltage controlledlight active device for emitting two or more colors of light. A firstelectrode and a second electrode are disposed adjacent to each otherwith a gap between them. A mixture of an organic light activeparticulate and a conductive carrier material is disposed within thegap. Because of the particulate/carrier mixture, the gap between theelectrodes (or whatever layers are sandwiching the organic emissivelayer) can be much wider than the thickness of the emissive particulate.The particulate is dispersed three dimensionally throughout a conductivecarrier. By this construction, many of the drawbacks, such as electricalshorts, delamination, etc., that plague the very thin polymer filmfabrication methods are overcome.

In the voltage controlled multi-color embodiment, the organic lightactive particulate is comprised of first emitting particles including afirst electroluminescent conjugated polymer. The first emittingparticles emit a number of photons of a first color in response to afirst turn-on voltage applied to the electrodes. The first emittingparticles also emit a different number of photons, zero or more, of thefirst color in response to other turn-on voltages. The organic lightactive particulate further comprises second emitting particles includinga second conjugated polymer. The second emitting particles emit a numberof photons of a second color in response to a second turn-on voltage anda different number of photons of the second color in response to otherturn-on voltages. Thus, in the case of a multi-colored diode or display,different colors are perceivable by the human eye depending on theapplied turn-on voltage.

The organic light active layer may also include third emitting particlesincluding a third electroluminescent conjugated polymer. The thirdemitting particles emit a number of photons of a third color and/orintensity in response to a third turn-on voltage applied to theelectrodes and a different number of photons of the third color and/orintensity in response to other turn-on voltages. A full color displaycan be obtained by incorporating an array of pixels, each capable ofemitting different colors, such as a first color red, a second colorgreen and a third color blue. The color emitters can be a mix of organicand inorganic materials. For example, an organic conjugated polymeremitter can be used as a red emitter and an inorganic rare earth metalor metal alloy, or doped inorganic semiconductor, can be used as a greenemitter. This combination of organic and inorganic emitters may expandthe potential candidates for emissive materials enabling the inventivedevice to be tuned for specific applications.

The voltage controlled organic light active device can be constructed asa display. In this case, the first electrode is part of an x-grid ofelectrodes and the second electrode is part of a y-grid of electrodes.The mixture of the organic light active particulate and the conductivecarrier material in the gap between the first electrode and the secondelectrode make up an emissive component of a pixel of a display device.Depending on the device structure it can be driven as a passive matrixor an active matrix device.

In accordance with the present invention, an organic light activedisplay device includes a substrate with a first grid of drivingelectrodes formed on the substrate. A second grid of electrodes isdisposed adjacent to the first grid of electrodes and defines a gapthere-between. A mixture of an organic light active particulate and aconductive carrier material is disposed within the gap. The organiclight active particulate includes first particles including a firstelectroluminescent conjugated polymer having a first turn-on voltage andsecond particles including a second electroluminescent conjugatedpolymer having a second turn-on voltage different than the first turn-onvoltage. When the first turn-on voltage is applied, a first color isemitted by the first electroluminescent conjugated polymer. Light havinga second color is emitted by the second electroluminescent conjugatedpolymer in response to the second turn-on voltage applied to the firstelectrode and the second electrode. Additional color emitters can beincluded, including emitters that emit photons predominately in thevisible and/or non-visible range of the photon radiation spectrum. Also,the color emitters can be comprised of other organic or inorganicmaterials.

In accordance with the present invention, a method is provided fordriving a multi-color light emitting device, the multi-color lightemitting device is capable of emitting two or more colors in sequence.Each color is emitted in response to a respective different appliedturn-on voltage. During an emission cycle, a first turn-on voltage isapplied having a duration to the light emitting device so that a firstburst of a predominant number of photons of a first color are emitted. Asecond turn-on voltage is then applied during the emission cycle havinga duration and at least one of a magnitude and a polarity different thana magnitude and polarity of the first turn-on voltage. For example, a 5volt turn-on voltage may cause a predominate emission of red photons,and a 10 volt turn-on voltage may cause a predominate emission of greenphotons. In response to the second turn-on voltage duration, a secondburst of a predominant number of photons of a second color are emitted.In this way, during the emission cycle the first burst and the secondburst, (and possibly third or more burst), occur in rapid succession. Ahuman eye and vision system receiving the first burst and the secondburst, and so on, is stimulated to perceive a color that is differentthan the first color and the second color (the emitted burst colors).

In accordance with another aspect of the present invention, a method isprovided for forming a layered organic light active materialparticulate. This layered organic light active material particulate ismixed with the conductive carrier material and disposed between theelectrodes to form the inventive light emitting devices. To form theparticulate, a first mixture is formed of a first organic light activecomponent material and a first carrier fluid. A second mixture is formedof a second organic light active component material and a second carrierfluid. A first mist is generated of the first mixture in an environmentso that a first particulate of the first organic light active componentmaterial is temporarily suspended in the environment. A second mist ofthe second mixture is generated in the environment so that a secondparticulate of the second organic light active component material istemporarily suspended in the environment. The first particulate and thesecond particulate are allowed to commingle and attract together in theenvironment to form a first layered organic light active materialparticulate. A charge of opposite polarity can be applied to theconstituents in each mist to promote electrical attraction. When thecharged particles join together an electrically neutral organic lightactive particulate is obtained. The layered organic light activeparticulate has a first layer made up of the first organic light activecomponent material and a second layer made up of the second organiclight active component material. Additional layers can be added to themultilayered structure by forming another mixture of another organiclight active component material and another carrier fluid and formingyet another mixture of a previously formed layered organic light activematerial particulate and yet another carrier fluid. The resultingparticles are suspended in the environment as described above andallowed to commingle and attract together to form the multilayeredparticulate structure. This method can be repeated to build upmultilayered organic light active material particulate having a range ofselectable electrical, optical, mechanical and chemical attributes.Further, depending on the desired particulate characteristics, theconstituents of the multilayered structure may be organic and/orinorganic materials. The use of organic and inorganic materials broadensthe potential candidates of materials that can be combined to form themultilayered particulate. Further, the inventive method may be appliedfor making multilayered particles for other applications, such as drugdelivery vehicles, electrical circuit components, bi-polarelectrophoretic microdevices, nanomachines, etc.

The environment in which the particulate is formed can be an inert gas,reactive gas, a vacuum, a liquid or other suitable medium. For example,it may be advantageous for the environment to include elements thatperform a catalytic function to promote a chemical reaction in orbetween the constituents in the mists. A characteristic enhancingtreatment may be performed on the formed layered organic light activematerial particulate. The treatment may be a temperature treatment, achemical treatment, a light energy treatment to cause, for example,light activated cross-linking, a shell forming treatment, or othercharacteristic enhancing treatment to impart desired attributes to theformed particulate. Further, it may be beneficial to form theparticulate under controlled conditions such as weightlessness. Thetreatments can be performed on the constituent materials and/or themultilayered particles to impart specific characteristics or improvedqualities. For example, a heat treatment may be performed to drive outmoisture or oxygen or other contaminants to increase the lifetime andemission efficacy of the particulate. A hot isostatic heat treatment canbe performed to enhance the interface between the constituent particlelayers. The particles can be brought up to about 80% of the melttemperature and placed under pressure in an inert atmosphere. Theinterface between the multilayers can then become diffused which mayresult in enhancements of the particulate characteristics.

In accordance with the present invention, an OLED device includes afirst electrode and a second electrode. The second electrode is disposedadjacent to the first electrode so that a gap is defined between them.Unlike the prior art, the present invention does not require theformation and preservation of thin films of OLED material with extremelywide surface area (as compared to the film thickness) and very littlematerial between the electrodes. Instead, the present invention utilizesOLED particulate dispersed within a conductive carrier. The OLEDparticulate is dispersed within the carrier material, which is disposedwithin the gap between the electrodes. When an electric potential isapplied to the electrodes, the electrical energy passes through thecarrier material raising the energy state of the OLED particulate,resulting in the emission of light.

In a simple form, the OLED particulate may comprise layered organicparticles, each particle including a hole transport layer and anelectron transport layer. A heterojunction is formed at the interfacebetween the hole transport layer and the electron transport layer. Eachlayered organic particle may also include a blocking layer adjacent tothe electron transport layer and an emissive layer adjacent to the holetransport layer (or other stack order and component layers), therebyforming a stacked organic layered structure. The blocking layer isprovided for facilitating the injection and combining of electrons andholes, and the emissive layer is provided for facilitating the emissionof photons when the energy state of the OLED particulate is raised.

In accordance with an aspect of the present invention, the OLEDparticulate comprises microcapsules. Each microcapsule includes aninternal phase and a shell.

The internal phase and/or the shell include the OLED material. Theinternal phase and/or the shell may also include a field reactivematerial. Depending on the OLED fabrication method and the desired OLEDcharacteristics, the field reactive material may be an electrostaticmaterial and/or a magnetically reactive material.

As described further herein, the microcapsule or particulate compositionmay be effective for enabling a “self healing” capability of thefabricated OLED device. In this case, the microcapsule includes acomposition that causes the microcapsule to rupture or otherwise changeshape if electrical energy above a threshold is applied to themicrocapsule. For example, a particular microcapsule may end uppositioned so that during use of the OLED device, it becomes a shortbetween the electrodes. The microcapsule may end up positioned adjacentto a dust particle or other foreign inclusion, creating such a short. Inthis case, electrical energy exceeding a predetermined threshold willpass through the microcapsule causing the capsule to become disruptedand disconnect the short. By this construction, the microcapsule isautomatically removed from the path of conduction of electrical energyin the event of a short. Further, a particulate mixture can includedifferent species of emitters. The different species can each have aparticular turn-on voltage. Two or more of the species can emit the samecolor of light, but have different turn-on voltages. Typically,different color emitters have different service lifetimes. For example,a blue emitter may have a shorter service life than a red emitter, and agreen emitter may have a service life between the other two. As theemitters of one color lose their potency, the display loses its colorvibrancy and display effectiveness. However, in accordance with thisaspect of the invention, more than one species of a specific color OLEDparticulate can be included in the particulate mixture. Each species hasa different turn-on voltage at which it most effectively emits thecolored light. The loss of intensity of, say, the blue emitter, can bedetected and the other blue emitter species driven by altering the pixeldriving voltage.

In accordance with another aspect of the invention, the microcapsuleshell and/or internal phase may include a composition effective toprovide a barrier against degradation of the OLED material. The OLEDmicrocapsules are dispersed within a carrier fluid. This carrier fluidalso provides a barrier against the intrusion of substances whichdegrade the OLED material.

The OLED microcapsules can have constituent parts including at least oneof hole transport material, electron transport material, field reactivematerial, solvent material, color material, shell forming material,barrier material, desiccant material, scavenger material, and heatmeltable material. The constituent parts form at least one internalphase and at least one shell. The constituent parts are selected so asto have electrical characteristics that result in a preferred path ofelectrical conduction through the hole transport material and theelectron transport material. By this construction, the microcapsulebehaves, for example, as a pn junction upon application of an electricalpotential to the first electrode and the second electrode.

The OLED device can be constructed of suitably chosen materials so thatthe carrier material is relatively less electrically conductive than theOLED particulate, this ensures that the OLED particulate offers a pathof less electrical resistance than the carrier material. Thus, theelectric potential applied to the electrodes will pass through thecarrier material, which has some electrical conductivity, and throughthe OLED particulate, which has relatively higher electricalconductivity. In this way, the preferred path of electrical conductionis through the OLED particulate. Likewise, the shell of the OLEDmicrocapsules are relatively less electrically conductive than the OLEDmaterial itself, so that the OLED material offers a path of lesselectrical resistance than the shell.

The typical OLED includes an OLED component that is a hole transportmaterial and an OLED component that is an electron transport material.In accordance with a formulation of the inventive microcapsules, theshell comprises an OLED component material that is either the holetransport material or the electron transport material, and the internalphase of the microcapsule includes the OLED component material that isthe other of the hole transport material and the electron transportmaterial. Depending on the desired optical qualities of the fabricatedOLED device, the carrier material can be selected so that it has opticalproperties during use of the OLED device that are transparent,diffusive, absorptive, and/or reflective to light energy. During thehardening process of the carrier, it can be selectively cured so that itis more light transmissive through the volume between the top and bottomelectrodes and less light transmissive or more light absorbing throughthe volume that is not between the electrodes. With this construction,the contrast of the display is improved and ambient light is absorbedrather than reflected from the display to reduce glare. Also, dependingon the composition of the carrier material and characteristic enhancingmaterial incorporated in it, the selective curing of the carrier fluidcan control the conduction of electrical energy through it. In this way,the volume between the pixels is controlled to be less conductive thanthe volume between the top and bottom electrodes of each pixel. Thismechanism further reduces cross talk between the pixels. Further, theOLED particulate may be more conductive than the carrier material. Thecomposition of the OLED particulate can be selected so that theelectrical characteristics of the OLED particulate includes an electroor magneto rheological characteristic. This rheological characteristicis effective for causing the OLED particulate to move within the carrierand orient in response to an applied electrical or magnetic field. Bymigrating the OLED particulate to the regions of the pixels during theparticulate aligning step, the carrier material volume between thepixels will have a lower conductivity than the volume between the topand bottom electrodes. This will also reduce cross talk between thepixels.

In accordance with another composition of the OLED microcapsule, theinternal phase comprises OLED material and a magnetically reactivematerial disposed within a first shell. An electrolyte and a curablefluid material are disposed surrounding the shell. A second shellencapsulates the first shell, the electrolyte and the curable material.In response to an applied magnetic field, the position of the firstshell is changeable relative to the second shell. Upon curing thecurable material, the position of the first shell relative to the secondshell is locked in place. As is described in detail herein, thismicrocapsule structure can be used to form capacitor/OLED microcapsuleswhich may be particularly effective for use in passive matrix displays.This construction can be used to form other electronically activemicrocapsules for forming electronic circuit components. For example,semiconductor characteristics of the OLED-type polymers and/or inorganicmaterials can enable transistor, capacitor and other electronic circuitelements to form, for example, memory, processing, transceivers, powersupplies and other electronic circuit devices.

In accordance with the present invention, a method for forming an OLEDdevice is provided. A top electrode and a bottom electrode are provideddefining a gap there between. Within the gap, a field reactive OLEDparticulate is disposed randomly dispersed within a fluid carrier. Analigning field is applied between the top electrode and the bottomelectrode to form a desired orientation of the field reactive OLEDparticulate within the fluid carrier. The fluid carrier comprises ahardenable material. While the desired orientation of the field reactiveOLED particulate is maintained, the carrier is cured to form a hardenedsupport structure within which is locked in position the OLEDparticulate. In some cases it may not be necessary to align theparticles by migration through the carrier fluid. They can remainrandomly dispersed, or simply rotated so that the bipolar particulate,for example, is properly oriented between the electrodes to improve theelectrical to light or light to electrical energy conversion.

The OLED particulate may comprise a bipolar OLED microcapsule. The OLEDparticulate is formed by the steps of first providing a first particlecomprised of a hole transport material. The hole transport material hasa net first electrical charge. A second particle comprised of anelectron transport material is provided having a net second electricalcharge. The first electrical charge is of opposite polarity from thesecond electrical charge. The first particle and the second particle arebrought together to form a unified OLED particulate having a holetransport layer and an electron transport layer forming a heterojunctionbetween them. The first particle may further include a photon-activelayer. This photon-active layer may be a light emissive layer in whichcase the OLED forms a light emitting device, or a light receptive layer,in which case the OLED forms a light detecting device.

The OLED particulate can be formed by microencapsulating an internalphase within a shell. The internal phase or the shell includes an OLEDmaterial and either the internal phase or the shell includes a fieldreactive material. The field reactive material comprises either or bothan electrostatic and a magnetically reactive material. In accordancewith another composition of the inventive microcapsule, the internalphase comprises an OLED emitter material and other materials (such as anOLED hole transport material) dispersed in solution and/or suspension,or a polymer blend. Color dyes may also be included within the internalphase or shell. The fluid within the internal phase may be a carrierfluid or solvent. In order to provide the alignment capabilities of themicrocapsules, either the internal phase or the shell may include afield reactive component.

In accordance with another aspect of the present invention, a stackedOLED device is provided. The inventive OLED device includes a first OLEDpixel layer comprised of a first layer electrode. A second layerelectrode is disposed adjacent to the first layer electrode. A firstlayer gap is defined between the electrodes. An OLED particulate isdispersed within a carrier and contained within the first layer gap. Atleast one subsequent OLED pixel layer is formed over the first OLEDpixel layer.

Each subsequent OLED pixel layer includes a first subsequent layerelectrode. A second subsequent layer electrode is disposed adjacent tothe first subsequent layer electrode defining a second layer gap therebetween. An OLED particulate in a carrier material is disposed betweenthe electrodes.

To achieve a full color OLED display, the OLED particulate of the firstOLED pixel layer emits light of a first wavelength range in response toa drive voltage being applied to the first layer electrode and thesecond layer electrode. Each subsequent OLED pixel layer emits light ofa different wavelength range in response to the driving voltage appliedto the respective electrode pairs so that an RGB color display can beformed.

Further, a dichromatic pixel layer can be formed adjacent to the lastsubsequent OLED pixel layer. The dichromatic pixel layer can be formedfrom an LCD display-type layer or from a electrophoretic microcapsuledisplay layer along the lines described in the 6,422,687 B1 patentissued to Jacobson. This dichromatic pixel layer, as described morefully herein, results in a display that can viewed in direct brightsunlight as well as with improved contrast in indoor ambient lightingconditions. Further, additional subsequent OLED pixel layers can beprovided which emit light in additional color range having a colorand/or light intensity different from the color and/or light intensityof the other OLED pixel layers. In this construction, the display can bedriven, for example, as an infrared display for stealth night-visionapplications.

Further, the inventive OLED device can be configured so as to detectlight impinging on a pixel grid formed in accordance with the presentinvention. In this case, the OLED particulate of a first OLED pixellayer emits an electrical energy in response to the reception of photonsand applies the electrical energy as a detectable signal to the firstand second layer electrodes. Further, a full color CCD-type camera canbe formed by tuning the wavelength range at which subsequent layers ofOLED pixels are photo reactive.

In accordance with another aspect of the present invention, a method isprovided for making a light active device. A mixture is providedcontaining a monomer and light active material. The light activematerial contains at least one of an energy-to-light material foremitting light in response to an applied electrical energy and aradiation-to-energy material and generating electrical energy inresponse to irradiation. The monomer is selectively cross-linked in apattern to form a polymer. As the cross-linking reaction progresses, themonomer migrates in response to the selective cross-linking pattern,causing the cross-linked monomer (a polymer) and the light activematerial to become concentrated in separate regions. The end result is asolid polymer with light active regions embedded in a patterncorresponding to the selective cross-linking pattern.

In accordance with another aspect of the present invention, a lightactive device is provided. Light active material is provided in a firstregion. A polymer is provided in a second region. The polymer is formedby selectively cross-linking a monomer from a mixture containing themonomer and the light active material. The selective cross-linkingcauses a concentration of the light active material at the first regionand a concentration of the polymer at the second region.

In accordance with another aspect of the present invention, a method isprovided for making a light emitting device. The inventive steps includeproviding a bottom substrate, with a bottom electrode over the bottomsubstrate. An emissive layer is disposed over the bottom electrode. Theemissive layer includes a mixture of a dispersed OLED particulate in amonomer fluid carrier. The monomer is selectively polymerized causingthe OLED particulate to concentrate in emissive regions and thepolymerized monomer to concentrate in polymerization regions.

In accordance with another aspect of the invention, a method is providedfor making a light emitting device. A bottom substrate is provided and abottom electrode provided over the bottom substrate. An emissive layercomprising a mixture including an emissive/more-conductive material anda non-emissive/less-conductive material is disposed over the bottomsubstrate. The mixture is selectively patterned causing theemissive/more-conductive material to concentrate in emissive regions andthe non-emissive/less-conductive material to concentrate in non-emissiveregions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive display fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream;

FIG. 2 illustrates a particle of OLED material for being dispersed in acarrier fluid in accordance with the inventive display fabricationmethod;

FIG. 3 illustrates an inventive microcapsule comprised of an internalphase of OLED material encapsulated within a polymer shell;

FIG. 4 illustrates an inventive bipolar microcapsule comprised of aninternal phase of OLED material encapsulated within a polymer shell;

FIG. 5 illustrates an inventive microcapsule comprised of a firstmicrocapsule including an internal phase of OLED material and magneticmaterial, along with a mixture of electrolyte and uncured monomer, allencapsulated within a polymer shell;

FIG. 6 illustrates an inventive microcapsule comprised of an internalphase of OLED material encapsulated within a double-wall shell, eachwall having a composition selected for imparting a desired electrical,optical, magnetic and/or mechanical property to the microcapsule;

FIG. 7 illustrates an inventive microcapsule comprised of an internalphase consisting of a mixture of OLED material with other components soas to tailor the electrical, optical, magnetic and/or mechanicalproperty of the microcapsule;

FIG. 8 illustrates an inventive microcapsule comprised of a firstmicrocapsule including an internal phase comprised of an OLED material,and a corrosion barrier material, all encapsulated within a polymershell;

FIG. 9 illustrates an inventive microcapsule comprised of a multi-walledmicrocapsule structure wherein layers of corrosion barrier material areencapsulated within polymer shells with an internal phase of OLEDmaterial;

FIG. 10 illustrates an inkjet-type or other nozzle fabrication methodfor forming a layer of OLED microcapsules dispersed within a lightcurable monomer carrier;

FIG. 11 illustrates a layer of OLED microcapsules fixed within a curedmonomer barrier disposed between a top electrode and a bottom electrode;

FIG. 12 illustrates sealed fabrication stations for forming a barrierprotected OLED microcapsule display stratum;

FIG. 13 illustrates an inventive display fabrication line using modularstations for forming various stratum of a thin, lightweight, flexiblewireless display;

FIG. 14 illustrates a highly organized OLED microcapsule structureformed in accordance with the inventive OLED device fabrication method;

FIG. 15 illustrates a chain structure of OLED microcapsules formed inaccordance with the inventive OLED device fabrication method;

FIG. 16 illustrates a full color OLED display formed in accordance withthe inventive OLED device fabrication method;

FIG. 17 illustrates a layer of conductive microcapsules for forming anelectrode layer in accordance with the inventive device fabricationmethod;

FIG. 18 illustrates the formation of OLED microcapsule chains formed onan electrode layer;

FIG. 19 illustrates the formation of OLED microcapsule chains formedbetween top and bottom electrode layers;

FIG. 20 illustrates the formation of OLED microcapsule chains within acured carrier for forming a corrosion barrier;

FIG. 21 illustrates a full color display formed in accordance with theinventive OLED device fabrication method;

FIG. 22 illustrates step one of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 23 illustrates step two of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 24 illustrates step three of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 25 illustrates step four of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 26 illustrates step five of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 27 illustrates step six of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 28 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the aligning field turned off;

FIG. 29 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the magnetic aligning field turned onwith uncured electrolyte mixture;

FIG. 30 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the magnetic aligning field turned onwith cured electrolyte mixture;

FIG. 31 shows a pixel comprised of a chain of capacitor OLED beingcharged by a charging voltage;

FIG. 32 shows a pixel comprised of a chain of capacitor OLED beingtriggered for light emission by a trigger voltage;

FIG. 33 shows OLED microcapsules randomly dispersed within a fluid buthardenable carrier fluid;

FIG. 34 shows OLED microcapsule chains aligned within an appliedaligning field formed within unhardened carrier fluid;

FIG. 35 shows OLED microcapsule chains aligned within an appliedaligning field held in alignment within hardened carrier;

FIG. 36 shows the OLED microcapsule structure shown in FIG. 35 with adrive voltage applied and light being emitted from the OLED microcapsulechains;

FIG. 37 illustrates a method for forming an OLED particulate having ahole transport layer and an electron transport layer;

FIG. 38 illustrates a method for forming an encapsulated OLEDparticulate;

FIG. 39 illustrates a first step in forming a multi-layered OLEDparticulate;

FIG. 40 illustrates a second step in forming a multi-layered OLEDparticulate;

FIG. 41 illustrates a third step in forming a multi-layered OLEDparticulate;

FIG. 42 schematically shows a full-color OLED display constructed inaccordance with the present invention, and having a dichromatic displaylayer for improving the display contrast, power efficiency and forproviding display viewing in bright sunlight;

FIG. 43 schematically shows the full-color OLED display shown in FIG.42, with the dichromatic pixels oriented for reflecting emitted OLEDlight;

FIG. 44 schematically shows the full-color OLED display shown in FIG.42, showing the relative strength of reflected light depending on thedichromatic pixel orientations;

FIG. 45 shows magnetically-active OLED microcapsules randomly dispersedwithin a fluid but hardenable carrier fluid along with desiccantparticulate;

FIG. 46 shows the magnetically-active OLED microcapsule chains alignedwithin an applied magnetic aligning field within the unhardened carrierfluid;

FIG. 47 shows the magnetically-active OLED microcapsule chains alignedwithin the applied magnetic aligning field held in position within thehardened carrier;

FIG. 48 shows the magnetically-active OLED microcapsule structure withlight being emitted from the OLED microcapsule chains;

FIG. 49 schematically illustrates a full color OLED display having highintensity visible light display layers and an infrared display layer;

FIG. 50 shows an OLED display layer and a liquid crystal display layer;

FIG. 51 shows an inventive OLED display fabricated with thin films oforganic material with photodetection elements and photodetection pixelelements;

FIG. 52 shows an OLED microcapsule wherein the shell is slightly lessconductive than the encapsulated OLED material;

FIG. 53 shows an OLED microcapsule wherein the OLED material isencapsulated along with an electrolyte and a magnetic inner microcapsulehaving an electrically insulative shell;

FIG. 54 shows an OLED microcapsule wherein the OLED material and thehole transport material are contained in solution within a conductiveshell;

FIG. 55 shows the OLED microcapsules shown in FIG. 54 including amagnetically active material and color dye in the inner phase and heatmeltable material in the shell;

FIG. 56 illustrates the OLED microcapsule shown in FIG. 54 used forcreating a general lighting or display back lighting OLED device;

FIG. 57 illustrates a transparent, flexible OLED display fabricated foruse as part of a vehicle windshield;

FIG. 58 is a block diagram showing the basic components of an activewindshield display system using an OLED display;

FIG. 59 illustrates an OLED light emissive element;

FIG. 60 shows the OLED light emissive element having a conventionallight bulb form factor;

FIG. 61 illustrates an OLED device fabricated using light emissivelayers and light detecting layers;

FIG. 62 illustrates stereoscopic goggles having OLED device elements;

FIG. 63 illustrates a flexible OLED display having a curvature thatcompensates for the human eye's range of motion;

FIG. 64 illustrates a flexible OLED display having optical lens elementsfor focusing emitted light at the appropriate physical location within ahuman eye;

FIG. 65 illustrates a wraparound visor having a curved, flexible OLEDdisplay and speakers;

FIG. 66( a) illustrates a wall of a house having an inventive OLEDdisplay window, the window being driven so as to be transparent withtrees outside the house visible through the window;

FIG. 66( b) illustrates the wall of a house having the inventive OLEDdisplay window, the window being driven so as to display multiplesimultaneous video stream including video phone communication, Internetweb page and a television program;

FIG. 66( c) illustrates the wall of a house having the inventive OLEDdisplay window, the window being driven so as to be a mirror;

FIG. 67( a) illustrates the use of an inventive flexible large formatdisplay as part of a camouflage system for a vehicle, such as a militarytank;

FIG. 67( b) illustrates the camouflage system shown in FIG. 67( a)wherein the display area has a curved viewing area;

FIG. 67( c) illustrates the use of an inventive flexible clothingdisplay as part of a camouflage system for a person;

FIG. 67( d) shows the inventive clothing camouflage system shown in FIG.67( b) in use;

FIG. 68( a) shows the use of flexible, lightweight solar panels as asunlight-to-energy system for powering an aircraft, such as a militaryobservation drone;

FIG. 68( b) is a block diagram illustrating some system elements of themilitary observation drone shown in FIG. 68( a);

FIG. 69 illustrates an embodiment of the inventive light active deviceshowing a semiconductor particulate randomly dispersed within aconductive carrier;

FIG. 70 illustrates an embodiment of the inventive light active deviceshowing the semiconductor particulate aligned between electrodes;

FIG. 71 illustrates an embodiment of the inventive light active deviceshowing semiconductor particulate and other performance enhancingparticulate randomly dispersed within the conductive carrier material;

FIG. 72 illustrates an embodiment of the inventive light active deviceshowing different species of organic light active particulate dispersedwithin a carrier material;

FIG. 73 illustrates an organic light active particle formed from apolymer blend;

FIG. 74 illustrates the polymer blend organic light active particulatedispersed within a conductive carrier;

FIG. 75 illustrates the polymer blend organic light active particleshowing light active sites;

FIG. 76 illustrates a polymer blend organic light active particulatehaving a field attractive constituent for aligning the particle in analigning field;

FIG. 77 illustrates composite microcapsules containing multilayeredorganic light active particles, each having a different light wavelengthemission and turn-on voltage;

FIG. 78 illustrates another composite microcapsule containingmultilayered organic light active particles, at least one having a fieldattractive constituent;

FIG. 79 illustrates three light emitting microcapsule species, eachspecies having a turn-on voltage controlled by the internal phasecomposition and the encapsulating shell composition;

FIG. 80 illustrates an embodiment of the inventive voltage controlledlight active device showing the composite microcapsule particulaterandomly dispersed within a carrier;

FIG. 81 illustrates an embodiment of the inventive voltage controlledlight active device showing the composite microcapsule particulatealigned between electrodes;

FIG. 82 illustrates the retinal response of the human eye to wavelengthsof light in the visible spectrum;

FIG. 83 illustrates the inventive primary color burst driving method forproducing a perceived full color image by the rapid and sequentialbursts of primary colored light emission;

FIG. 84 illustrates the inventive retinex burst driving method forproducing a perceived full color image by the rapid and sequentialbursts of colored light emission;

FIG. 85 illustrates the inventive adjusted color burst driving methodfor producing a perceived full color image by the rapid and sequentialbursts of adjusted colored light emission;

FIG. 86 is a flow chart showing the steps of the inventive method forforming a multilayered organic light active material particulate;

FIG. 87 illustrates a layered organic light active material particulateformed by the commingling of a particle of hole transport material witha particle of emissive layer material;

FIG. 88 illustrates the inventive method of forming a layered organiclight active material particulate from a hole transport constituent andan emissive layer constituent;

FIG. 89 illustrates a multi-layered organic light active materialparticulate formed by the commingling of a layered particle of holetransport/emissive layer material with a particle of electron transportmaterial;

FIG. 90 illustrates the inventive method of forming a multi-layeredorganic light active material particulate from a hole transport/emissivelayer constituent and an electron transport constituent;

FIG. 91 illustrates a layered organic light active material particulateformed by the commingling of a particle of blocking material with aparticle of electron transport material;

FIG. 92 illustrates the inventive method of forming a layered organiclight active material particulate from a blocking constituent and anelectron transport constituent;

FIG. 93 illustrates a layered organic light active material particulateformed by the commingling of a particle of emissive layer material witha particle of hole transport material;

FIG. 94 illustrates the inventive method of forming a layered organiclight active material particulate from an emissive layer constituent anda hole transport constituent;

FIG. 95 illustrates a multi-layered organic light active materialparticulate formed by the commingling of a layered particle ofblocking/electron transport material with a layered particle of emissivelayer/hole transport material;

FIG. 96 illustrates the inventive method of forming a multi-layeredorganic light active material particulate from a blocking/electrontransport constituent and a hole transport/emissive layer constituent;

FIG. 97 illustrates a layered organic light active material particulateformed by the commingling of a particle of field attractive materialwith a particle of electron transport material;

FIG. 98 illustrates the inventive method of forming a layered organiclight active material particulate from a field attractive constituentand an electron transport constituent;

FIG. 99 illustrates a layered organic light active material particulateformed by the commingling of a particle of emissive layer material witha particle of hole transport material;

FIG. 100 illustrates the inventive method of forming a layered organiclight active material particulate from an emissive layer constituent anda hole transport constituent;

FIG. 101 illustrates a multi-layered organic light active materialparticulate formed by the commingling of a layered particle of fieldattractive/electron transport material with a layered particle ofemissive layer/hole transport material;

FIG. 102 illustrates the inventive method of forming a multi-layeredorganic light active material particulate from a fieldattractive/electron transport constituent and a hole transport/emissivelayer constituent;

FIG. 103 is a cross section of a coated cathode fiber having a blockinglayer formed on the cathode fiber and an electron transport layer formedon the blocking layer;

FIG. 104 is a cross section of a coated anode fiber having a holetransport layer formed on the anode fiber and an emissive layer formedon the hole transport layer;

FIG. 105 illustrated the coated cathode fiber and the coated anode fibertwisted together to form an emissive fiber;

FIG. 106 shows a method for coating an electrode wire with organic lightactive device material;

FIG. 107 is a schematic view of a fabrication line utilizing theinventive OLED particulate/conductive carrier mixture;

FIG. 108 shows the step of printing an electrode pattern on a polymersheet substrate;

FIG. 1 illustrates the expanded gap distance between electrodes inaccordance with the present invention;

FIG. 110 illustrates a single layered multi-color pixel in accordancewith the present invention;

FIG. 111 illustrates a prior art OLED device;

FIG. 112 illustrates a prior art OLED device showing a dust particlecreating an electrical short between electrodes;

FIG. 113 illustrates a prior art OLED device showing the degradation ofthe organic thin film stack by the ingress of oxygen and water throughthe substrates;

FIG. 114 is a cross sectional schematic view illustrating the extrusionof light active fiber having aligned OLED particulate;

FIG. 115 is a perspective schematic view illustrating the extrusion oflight active fiber;

FIG. 7 is a cross section of a segment of extruded light active fiberFIG. 117 is a schematic view of the segment of extruded light activefiber driven by a voltage applied between electrodes;

FIG. 118 is a cross sectional schematic view illustrating an extrudedlight active fiber having a conductive electrode core and a transparentelectrode coating;

FIG. 119 is a perspective schematic view illustrating the extrusion ofthe light active fiber having a conductive electrode core and atransparent electrode coating;

FIG. 120 illustrates an extruded light active fiber having a conductiveelectrode core and a transparent electrode coating connected with avoltage source;

FIG. 121 is a cross sectional schematic view illustrating the extrusionof light active ribbon having aligned OLED particulate;

FIG. 122 is a perspective schematic view illustrating the extrusion oflight active ribbon;

FIG. 123 is a segment of extruded light active ribbon;

FIG. 124 is a cross-sectional view of the segment of extruded lightactive ribbon having wire electrodes incorporated within the ribbon anddriven by a voltage applied between electrodes;

FIG. 125 illustrates a light active fiber extrusion and choppingmechanism for forming uniform lengths of OLED light active fiber;

FIG. 126 illustrates OLED light active fiber randomly dispersed betweentwo electrodes;

FIG. 127 illustrated the OLED light active fibers aligned between thetwo electrodes;

FIG. 128 illustrates OLED light active fibers randomly dispersed betweentwo electrodes having a gap distance close to the uniform length of thefibers;

FIG. 129 illustrated the OLED light active fibers aligned between thetwo electrodes having a gap distance close to the uniform length of thefibers;

FIG. 130 illustrates light active fibers woven into carpeting;

FIG. 131 illustrates a light active cloth weave;

FIG. 132 illustrates a curved large format surround display formed inaccordance with the present invention by tiling length of displaysections;

FIG. 133 illustrates a method of forming two layer ultra-thinmultilayered OLED fiber by drawing and thinning;

FIG. 134 illustrates a method of forming four layer ultra-thinmultilayered OLED fiber by drawing and thinning;

FIG. 135 is a cross sectional view showing a wire having an electrontransport coating layer;

FIG. 136 is a cross sectional view showing a wire having a holetransport coating layer;

FIG. 137 illustrates coated wire intersecting electrodes for forminglight emitting pixels at the intersections;

FIG. 138 illustrates the inventive OLED particulate/conductive carriermixture formulated for being formable into useful products throughplastic molding techniques;

FIG. 139 illustrates an inventive OLED solid state light having aconventional light bulb form factor;

FIG. 140 illustrates a step of spray painting a reflective conductivelayer of an OLED device;

FIG. 141 illustrates a step of spray painting an emissive layer of anOLED device;

FIG. 142 illustrates a step of spray painting a transparent electrode ofan OLED device;

FIG. 143 illustrates a step in an inventive method for making a lightactive device showing a light active mixture disposed between an x and yelectrode grid;

FIG. 144 illustrates another step in the inventive method for making alight active device, showing a polymerization/migration step;

FIG. 145 illustrates another step in the inventive method for making alight active device, showing an aligning step;

FIG. 146 illustrates another step in the inventive method for making alight active device, showing a controlled pixelated light emission;

FIG. 147 illustrates a step in an inventive method for making a lightactive device, showing a bottom substrate having a bottom electrodepattern formed thereon;

FIG. 148 illustrates another step in the inventive method for making alight active device, showing a light active mixture disposed at a lightactive layer over the bottom electrode pattern;

FIG. 149 illustrates another step in the inventive method for making alight active device, showing the patterning of the light active layer byirradiation through a mask;

FIG. 150 illustrates another step in the inventive method for making alight active device, showing the migration of light active material intolight active regions;

FIG. 151 illustrates the composition of constituents in a multi-colorlight active mixture;

FIG. 152 illustrates a step in an inventive method for making amulti-color light active device, showing a multi-color light activemixture disposed over a patterned bottom electrode grid;

FIG. 153 illustrates a step in the inventive method for making amulti-color light active device, showing the selective patterning of oneof the color light active regions;

FIG. 154 illustrates a step in the inventive method for making amulti-color light active device, showing the patterned color lightactive regions;

FIG. 155 illustrates a full-color light active device having red, greenand blue side-by-side patterned color light active regions;

FIG. 156 illustrates a step in an inventive method for making apixilated light active device; showing a mixture of light activematerial disposed over a patterned bottom electrode grid;

FIG. 157 illustrates another step in the inventive method for making apixilated light active device, showing selective patterning through apixel grid mask;

FIG. 158 illustrates another step in the inventive method for making apixilated light active device, showing the migration of light activematerial to pixel regions;

FIG. 159 illustrates the composition of constituents in a light activedevice having pixels and conductive pathways formed by a self-assemblyprocess;

FIG. 160 illustrates a step in an inventive method for making a lightactive device having pixels and conductive pathways formed by aself-assembly process;

FIG. 161 illustrates another step in the inventive method for making alight active device by self-assembly, showing the selective patterningof the conductive pathways by irradiation through a mask;

FIG. 162 illustrates another step in the inventive method for making alight active device by self-assembly, showing the patterned conductivepathways;

FIG. 163 illustrates another step in the inventive method for making alight active device by self-assembly, showing the selective patterningof pixel regions by irradiation through a mask;

FIG. 164 illustrates another step in the inventive method for making alight active device by self-assembly, showing the patterned pixelregions and conductive pathways;

FIG. 165 schematically illustrates a light active device made byself-assembly, showing emissive/more conductive zones, non-emissive/moreconductive zones and non-emissive/lass conductive zones;

FIG. 166 illustrates a cubic volume of a randomly dispersed light activematerial in a light polymerizable monomer carrier; and

FIG. 167 illustrates the cubic volume shown in FIG. 166, showing thelight active material and polymerized carrier after holographicpatterning using an interference pattern generated by laser beams.

DETAILED DESCRIPTION OF THE INVENTION

For purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, there being contemplated such alterationsand modifications of the illustrated device, and such furtherapplications of the principles of the invention as disclosed herein, aswould normally occur to one skilled in the art to which the inventionpertains.

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive display fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream. FIG. 1 illustrates an embodiment of aninventive thin, lightweight, flexible, bright, wireless display showingthe simultaneous display of three received display signal. The wirelessdisplay utilizes a simple DSP and transceiver. It has a unique printedbattery power supply and printed user-input mechanism.

The inventive thin, lightweight, flexible, bright, wireless displayincludes a flexible substrate to provide a support structure upon whichcomponents can be manufactured by a fabrication method. As described inthe co-owned U.S. patent application Ser. No. 10/234,302, entitled “AThin, Lightweight, Flexible, Bright, Wireless Display”, the disclosureof which is incorporated by reference herein, a unique and effectivemethod for transmitting display information to a single or multipledisplays enables such displays to not have to have substantial onboardstorage or processing power. In accordance with this aspect of theinvention, the energy drain, bulk, weight and cost normally associatedwith such devices is avoided, and the durability and convenience of thedisplay is increased. Further, as shown schematically in FIG. 1,multiple streams of display information can be simultaneously receivedand displayed. For example, broadcast video content such as a televisionprogram may be shown at a first portion of the display, personalizedvideo content, such as a videophone conversation may be shown at asecond portion and a web page, including mapped hyperlink content, maybe shown at a third portion. Most of the processing, networking, signaltuning, data storage, etc., etc., that it takes to create such a set ofdisplayed content streams is not performed by the inventive wirelessdisplay. Other devices, such as a centralized computer, A/V or gatewaydevice perform these functions thus allowing the opportunity for theinventive display to have tremendous mobility and convenience.

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream. In accordance with the present invention, athin, lightweight, flexible, bright wireless display is obtained havingcomponents capable of being manufactured by the inventive fabricationmethod. The present invention enables a low cost, flexible, robust, fullcolor video display to be obtained. This wireless display is capable ofreceiving multiple display information signals and displaying thesimultaneous screens of the received display information inre-configurable formats. A relatively simple signal receiving andprocessing circuit, using, for example, a digital signal processor suchas those available from Texas Instruments, Texas or Oxford Microdevices,Connecticut, enables multiple video and still image screens to bedisplayed. An inventive manufacturing method described herein and in theco-owned patent application Ser. No. 10/234,301, filed Sep. 4, 2002entitled “Printer and Method for Manufacturing Electronic Circuits andDisplays” (incorporated by reference herein) enables the inventivewireless display to be fabricated at low cost and with the advantageousfeatures described herein. As will be described in more detail, aflexible substrate provides a support structure upon which componentscan be manufactured by a fabrication method. A display stratum includeslight emitting pixels for displaying information. The light emittingpixels are formed, by printing or otherwise forming a pixel layer(s) oflight-emitting conductive polymer. An electronic circuit stratumincludes signal transmitting components for transmitting user inputsignals to a display signal generating device for controlling displayinformation transmitted from the display signal generating device.Signal receiving components receive the display information transmittedfrom the display signal-generating device. Display driving componentsdrive the display layer according to the received display information. Auser input stratum receives user input and generates the user inputsignals. A battery stratum provides electrical energy to the electroniccircuit stratum, the user input stratum and display stratum components.The signal receiving components may include first radio frequencyreceiving components for receiving a first display signal having firstdisplay information carried on a first radio frequency and second radiofrequency receiving components for receiving a second display signalhaving second display information carried on a second radio frequency.In this manner, two or more simultaneously transmitted video displayscan be simultaneously displayed. The display driving components mayinclude signal processor components for receiving the first displaysignal and the second display signal and generating a display drivingsignal for simultaneously displaying the first display information at afirst location on the display stratum and the second display informationat a second location on the display stratum. At least some of thecomponents in the battery, display, user input and electronic circuitstratums can be formed by printing electrically active material to formcircuit elements including resistors, capacitors, inductors, antennas,conductors and semiconductor devices.

The inventive thin, lightweight, wireless display includes OLAMfabrication, such as that described herein. In accordance with thepresent invention, microcapsule 10 or particulate are randomly dispersedwithin a monomer carrier fluid 12 that is injected or otherwise disposedbetween two electrodes 14. Generally, the term particulate can referherein to particles of material or microcapsules 10, and vice-versa. Themicrocapsules 10 may include additives that impart rheological and/orphoretic properties. The microcapsules 10 form chains between theelectrodes 14 when a voltage is applied. Holding the voltage to keep thechains formed, the carrier fluid 12 is polymerized and the OLAMmicrocapsule chains locked into alignment between the electrodes 14. Thethus formed OLAM pixels emit light (or detect or convert light intoelectricity). The problem of contamination of the OLAM material is themajor factor limiting the display life span, and thus far has been a barto commercial success. The inventive fabrication method results in themoisture sensitive OLAM material being protected by the microcapsuleshell and the cured carrier 12. The pixel alignment is automatic, sincethe microcapsule chains are formed only between the electrodes 14. Thispixel array structure also greatly limits cross talk between pixels andthe optical properties of the cured monomer can be controlled to improvecontrast, display brightness, transparency, etc.

Solar cell components or layers can be used to “recycle” the energyemitted by the OLED emitters. Some of the emitted and ambient lightenergy impinges on the solar cells and generate electricity. This, alongwith the inventions described herein and the sheet battery described inthe above-referenced co-owned patent application Ser. No. 10/234,301,filed Sep. 4, 2002 entitled “Printer and Method for ManufacturingElectronic Circuits and Displays”, can enable lightweight, relativelyinexpensive, dichromatic newspapers (as described herein in FIG. 1) thatrecharge in sunlight (or even indoor ambient light) to enable full-coloremissive video display.

FIG. 2 illustrates a particle of OLED material for being dispersed in acarrier fluid 12 in accordance with the inventive display fabricationmethod. A typical OLED organic stack consists of a layer of holetransport material and a layer of electron transport material. In theconventional art, these layers are formed by spin coating, vacuumdeposition or inkjet printing. In accordance with the present invention,the OLED material is provided as particulate dispersed within a carrier12 material. The carrier 12 material with the dispersed particulate isdisposed between electrodes 14.

Electrical potential applied to the electrodes 14 causes light emissionto occur within the OLED particulate. In accordance with the presentinvention, the OLED phenomenon can be used to create general orspecialty lighting devices, monochrome or color displays, stereoscopicvision aids, digital maps and newspapers, advanced vehicle windshieldsand the like. Also, the particulate can be organic light active material(“OLAM™”) that is capable of generating a flow of electrons in responseto impinging light energy. This phenomenon can be used to createphotodetectors, cameras, solar cells and the like. In this application,where appropriate, the term OLED can mean a light emissive or a lightdetective material configuration.

FIG. 3 illustrates an inventive microcapsule 10 comprised of an internalphase of OLAM material encapsulated within a polymer shell. To create apath of least resistance through the OLED material, the shellcomposition is selected to be less conductive than the OLED material.

FIG. 4 illustrates an inventive electrostatically active microcapsule 10comprised of an internal phase of OLED material encapsulated within apolymer shell. The shell is composed of a material that can be orientedby the application of an electric field. The electrical properties ofthe shell enable the microcapsules 10 to be aligned into a desiredformation within a fluid carrier 12 in response to an applied electricfield.

FIG. 5 illustrates an inventive microcapsule 10 comprised of a firstmicrocapsule 10 including an internal phase of OLED material andmagnetic material, along with a mixture of electrolyte and uncuredmonomer, all encapsulated within a polymer shell. The magneticproperties of the magnetic material enable the microcapsules 10 to bealigned into a desired formation within a fluid carrier 12 in responseto an applied magnetic field.

FIG. 6 illustrates an inventive microcapsule 10 comprised of an internalphase of OLED material encapsulated within a double-wall shell, eachwall having a composition selected for imparting a desired electrical,optical, magnetic and/or mechanical property to the microcapsule. Inaccordance with the present invention, the OLED particulate comprisesmicrocapsules 10. For example, the microcapsule 10 includes an internalphase and a shell that is composed of material selected according to adesired combination of electrical, mechanical, optical and magneticproperties. The internal phase and/or the shell may include the OLEDmaterial. The internal phase and/or the shell may also include a fieldreactive material. Depending on the OLED fabrication method and thedesire OLED characteristics, the field reactive material may be anelectrostatic material and/or a magnetically reactive material. Themicrocapsule 10 composition may be effective for enabling a “selfhealing” capability of the fabricated OLED device. In this case, themicrocapsule 10 includes a composition that causes the microcapsule 10to rupture if electrical energy above a threshold is applied to themicrocapsule. A heat meltable material that heats up when electricalenergy above a threshold is applied can be incorporated as themicrocapsule shell. For example, if a particular microcapsule 10 ends uppositioned so that during use of the OLED device it becomes a shortbetween the electrodes 14, or if the microcapsule 10 is adjacent to adust particle or other foreign inclusion, creating such a short, when anelectric potential is applied between the electrodes 14, energyexceeding a predetermined threshold will pass through the microcapsule10 causing the capsule to rupture and disconnect the short. By thisconstruction, the microcapsule 10 is automatically removed from the pathof conduction of electrical energy in the event of a short.

FIG. 7 illustrates an inventive microcapsule 10 comprised of an internalphase consisting of a mixture of OLED material with other components soas to tailor the electrical, optical, magnetic and/or mechanicalproperty of the microcapsule. The other components can be fieldreactive, such as magnetic or electrostatically reactive materials forimparting orientation and aligning properties. Heat expandable materialscan be included to provide the microcapsule 10 with the ability to burstor otherwise change shape or electrical characteristic in response to anelectrical short to disconnect the microcapsule 10 and overcome theelectrical short. Colorants, such as dyes and colored particles can beincluded to tune the light emitted from the microcapsule. Desiccantand/or scavenger material can be included to provide protection againstcontamination of the OLED material.

FIG. 8 illustrates an inventive microcapsule 10 comprised of a firstmicrocapsule 10 including an internal phase comprised of an OLEDmaterial, and a corrosion barrier material, all encapsulated within apolymer shell. In accordance with this aspect of the invention, themicrocapsule shell and/or internal phase may include a compositioneffective to provide a barrier against degradation of the OLED material.The OLED microcapsules 10 are dispersed within a carrier fluid 12. Thiscarrier fluid 12 also provides a barrier against the intrusion ofsubstances which degrade the OLED material.

FIG. 9 illustrates an inventive microcapsule 10 comprised of amulti-walled microcapsule 10 structure wherein layers of barriermaterial are encapsulated within polymer shells with an internal phaseof OLED material. As in the microcapsule 10 shown in FIG. 7, within theshell of the microcapsule 10 other components can be included that arefield reactive, such as magnetic or electrostatically reactive materialsfor imparting orientation and aligning properties. Heat expandablematerials can be included to provide the microcapsule 10 with theability to burst in response to an electrical short to disconnect themicrocapsule 10 and overcome the electrical short. Colorants, such asdyes and colored particles can be included to tune the light emittedfrom the microcapsule. Desiccant, getter and scavenger material can beincluded to provide protection against contamination of the OLEDmaterial.

FIG. 10 illustrates an inkjet-type or other nozzle 36 fabrication methodfor forming a layer of OLED microcapsules 10 dispersed within a lightcurable monomer carrier 12. OLED microcapsules 10 dispersed in anuncured monomer carrier fluid 12 can be utilized with inkjet printingtechnology to create a film of OLED microcapsules 10 contained withflexible cured monomer. The inkjet-type or other nozzle fabricationtechnique, such as slot-die, can be utilized to form controlled OLEDdeposition, with the OLED contained within a curable carrier 12. As isdescribed elsewhere herein, desiccant particulate can be included withinthe carrier 12 to enhance the protection of the OLED material.

FIG. 11 illustrates a layer of OLED microcapsules 10 fixed within acured monomer barrier disposed between a top electrode 14 and a bottomelectrode 14. The cured monomer and the shell of the microcapsules 10provide a barrier to contamination from water vapor and oxygen. The OLEDdevice can be constructed of suitably chosen materials so that thecarrier material 12 is relatively less electrically conductive than theOLED particulate, this ensures that the OLED particulate offers a pathof less electrical resistance than the carrier material 12. Thus, theelectric potential applied to the electrodes 14 will pass through thecarrier material 12, which has some electrical conductivity, and throughthe OLED particulate, which has relatively higher electricalconductivity. In this way, the preferred path of electrical conductionis through the OLED particulate. Likewise, the shell of the OLEDmicrocapsules 10 is relatively less electrically conductive than theOLED material itself, so that the OLED material offers a path of lesselectrical resistance than the shell. Field-attractive microcapsules 10containing OLED material randomly dispersed within a monomer carrierfluid 12 are injected or otherwise disposed between two electrodes 14.The microcapsules 10 may include additives that impart electro ormagneto rheological-type properties. When used for a pixilated displaylayer, the microcapsules 10 form chains between the electrodes 14 whenan aligning field is applied. Holding the aligning field to keep thechains formed, the carrier fluid 12 is polymerized and the OLEDmicrocapsule chains are locked into alignment between the electrodes 14.

The problem of contamination of the OLED material is the major factorlimiting the display life span, and thus far has been a bar tocommercial success. The inventive fabrication method results in themoisture and oxygen sensitive OLED material being protected by themicrocapsule shell and the cured carrier 12, and the pixel alignment isautomatic, since the microcapsule chains are formed only between theelectrodes 14 or where the aligning field is applied. This pixel arraystructure also greatly limits cross talk between pixels and the opticalproperties of the cured carrier 12 can be controlled to improvecontrast, display brightness, transparency, etc. The OLED particulate ina carrier 12 disposed between two or more electrodes 14 can be utilizedto create roll-to-roll sheets of displays or lights, used as “filament”in a light bulb, used to form solar cells, solar cell housing shingles,light detectors, cameras, vision aides, heads-up display windshields andthe like. This OLAM construction can even be formed as fibers for lightemitting flooring, wall coverings, specialty lighting, clothing, shoes,building materials, furniture, etc. The OLAM material can be injectionmolded, or otherwise formed using known polymer fabrication methods.

FIG. 12 illustrates sealed fabrication stations 22 for forming a barrierprotected OLED microcapsule display stratum. The microcapsules 10 aredispersed in a carrier fluid 12. The upper and lower plates 16 controlthe intensity of the attraction toward and/or between the flexiblesubstrate 24 and sheet electrode 14. Seals 18 keep out water and air,using a vacuum airlock. The curing station 20 cures the carrier fluid 12into a flexible water and oxygen barrier. The microcapsules 10 can befor forming emitters, detectors, various electronic circuit elements (asdescribed in the referenced co-owned patent application). Themicrocapsules 10 may also be for adding other mechanical (structure,expansive, meltable, desiccant, etc.), optical (reflective, diffusive,opaque, colorant, etc.), electrical (conductive, resistive,semi-conductive, insulative, etc.). The upper and lower plate 16 s arecontrolled to vary the attractive and/or aligning field and createcontrolled accumulations and alignments of the microcapsules 10. Theviscosity of the fluid can also be controlled to control theaccumulations of microcapsules 10 (for three-dimensional buildup,control spread of pixels, etc.). As an example, lower viscosity carrierfluid 12 with an agitator may be preferred. There can be, for example,two simultaneously applied aligning fields, magnetic and electrostatic.A mix of microcapsules 10 can be dispersed, (e.g., magnetically andconductive OLED microcapsules 10 and electro-statically conductiveinsulators for creating a more controllable path of least resistance).

FIG. 13 illustrates an inventive display fabrication line using modularprinters for forming various stratum of a thin, lightweight, flexiblewireless display. Display fabrication line uses mix of differentfabrication stations 22. Examples of fabrication stations 22 can befound in co-owned U.S. patent application Ser. No. 10/234,301, filedSep. 2, 2002 entitled “Printer and Method for Manufacturing ElectronicCircuits and Displays”. The various layers of a display include battery,electronic circuit, user input and display stratums are formed atdifferent fabrication stations 22. In accordance with the presentinvention, fabrication stations 22 for forming an OLED light emissivedevice is provided. A top electrode 14 and a bottom electrode 14 definea gap there between. Disposed within the gap, field reactive OLEDparticulates are randomly dispersed within a fluid carrier 12. Dependingon the device being fabricated, an aligning field may be applied betweenthe top electrode 14 and the bottom electrode 14 to form a desiredorientation of the field reactive OLED particulate within the fluidcarrier 12 between the top electrode 14 and the bottom electrode 14. Thecarrier 12 comprises a hardenable material, such as a light-curableliquid monomer. The carrier 12 is cured to form a hardened carrier 12for maintaining the desired orientation of the field reactive OLEDparticulate within the hardened carrier 12. The OLED particulate maycomprise a bipolar OLED microcapsule 10 or other OLED-based structurethat is capable of forming chains between the electrodes 14.

Depending on the quality of the barrier created by the inventivefabrication method, there may be no need for additional barrier layers30 other than substrates 24 since cured carrier 12 and microcapsuleshells protect OLED material from water vapor and oxygen. Alternatively,additional barrier layers 30, including monomer, polymer, ceramic orthin metal layers can be included in the structure as needed to protectthe OLED material from contamination. Each color layer can be built onthe previous by fabrication method. The conductors 26 that make up thepixel electrodes 14 can also be used to fabricate the OLED microcapsule10 structure. In this case the substrate 24 and pixel electrode 14 gridbecome integral parts of the completed OLED device. Further, theelectric field created by applying voltage to the electrodes 14 can beused to align the OLED microcapsules 10 in chains as shown elsewhereherein. The mechanism for this alignment is similar to the phenomenonthat causes electro-rheological fluids to form chains within a carrierfluid 12. In this case, the OLED microcapsule 10 or the OLED particleitself includes the appropriate material component that enables theelectro-rheological effect. In addition, or alternatively, magneticmaterial can be employed with a magnetic field being applied as thealigning field. The light emitted from the OLED material when energizedby the applied voltage can be used to cure the monomer surrounding themicrocapsules 10. Thus, the voltage applied to the electrodes 14 duringdevice fabrication are utilized to form the pixel orientation andsimultaneously cure the barrier material.

FIG. 14 illustrates a highly organized OLED microcapsule 10 structureformed in accordance with the inventive OLED device fabrication method.Pixels can be controlled down to the microcapsule 10 size, spaced apartas needed. The conductive shell having a semi-insulative orsemi-conductive electrical property. The insulative or semiconductorshell creates a preferred path for the electron movement. By controllingthe conductivity of the cured carrier fluid 12, the preferred path canbe more pronounced through the OLED material.

FIG. 15 illustrates a chain structure of OLED microcapsules 10 formed inaccordance with the inventive OLED device fabrication method. Chains ofmicrocapsules 10 can be formed encased in a somewhat opaque curedcarrier 12, creating more intense columns of light and defined pixels,or the carrier 12 can be an optical diffusion layer to create a mixingof light from adjacent pixels (with electrical cross talk between thepixels reduced or eliminated by the inventive OLED device structure).Depending on the desired optical qualities of the fabricated OLEDdevice, the carrier material can be selected so that it has opticalproperties during use of the OLED device that are transparent,diffusive, absorptive, and/or reflective to light energy. During thehardening process of the carrier, it can be selectively cured so that itis more light transmissive through the volume between the top and bottomelectrodes and less light transmissive or more light absorbing throughthe volume that is not between the electrodes. With this construction,the contrast of the display is improved and ambient light is absorbedrather than reflected from the display to reduce glare. Also, dependingon the composition of the carrier material and characteristic enhancingmaterial incorporated in it, the selective curing of the carrier fluidcan control the conduction of electrical energy through it. In this way,the volume between the pixels is controlled to be less conductive thanthe volume between the top and bottom electrodes of each pixel. Thismechanism further reduces cross talk between the pixels. In accordancewith the present invention, an OLED device includes a first electrode 14and a second electrode 14. The second electrode 14 is disposed adjacentto the first electrode 14 so that a gap is defined between them.

An OLED particulate is dispersed within a carrier material 12, which isdisposed within the gap. When an electric potential is applied to theelectrodes 14, the electrical energy passes through the carrier material12 raising the energy state of the OLED particulate, resulting in theemission of light. The typical OLED includes an OLED component that is ahole transport material and an OLED component that is an electrontransport material. In accordance with a formulation of the inventivemicrocapsules 10, the shell comprises an OLED component material that iseither the hole transport material or the electron transport material,and the internal phase of the microcapsule 10 includes the OLEDcomponent material that is the other of the hole transport material orthe electron transport material. Depending on the desired opticalqualities of the fabricated OLED device, the carrier 12 material can beselected so that it has optical properties during use of the OLED devicethat are transparent, diffusive, absorptive, and/or reflective to lightenergy, and/or have such optical properties tuned for specificwavelengths of light.

FIG. 16 illustrates a full color OLED display formed in accordance withthe inventive OLED device fabrication method. The inventivemicrocapsule/particulate fabrication is used to create a full coloremissive display. Pixels can be controlled down to themicrocapsule/particulate size, spaced apart as needed. The conductiveshell can have a semi-conductive, conductive or an insulative overshell. The composition creates a preferred path for the electronmovement. By controlling the conductivity of the cured carrier fluid 12,the preferred path can be more pronounced. The inventive OLED deviceincludes a first OLED pixel layer comprised of a first layer electrode14. A second layer electrode 14 is disposed adjacent to the first layerelectrode 14. A first layer gap is defined between the electrodes 14. AnOLED particulate is dispersed within a carrier 12 and contained withinthe first layer gap. At least one subsequent OLED pixel layer is formedover the first OLED pixel layer. Each subsequent OLED pixel layerincludes a first subsequent layer electrode 14. A second subsequentlayer electrode 14 is disposed adjacent to the first subsequent layerelectrode 14 defining a second layer gap there between. An OLEDparticulate in a carrier material 12 is disposed between the electrodes14. To achieve a full color OLED display, the OLED particulate of thefirst OLED pixel layer emits light of a first wavelength range inresponse to a drive voltage being applied to the first layer electrode14 and the second layer electrode 14. Each subsequent OLED pixel layeremits light of a different wavelength range in response to the drivingvoltage applied to the respective electrode 14 pairs so that an RGBcolor display can be formed.

FIG. 17 illustrates a layer of conductive microcapsules 10 for formingan electrode layer in accordance with the inventive device fabricationmethod. The buildup of microcapsule layers may occur in successivefabrication steps. The conductor 26 may be microencapsulated, or just afield attractive material. For example, a ferrous metal powder can bemagnetically attracted to form one or more of the conductors. The OLEDmicrocapsule 10 can be electrostatic or magnetically attractive. Thecarrier substrate 24 has to pass the applied field, and a second, morerobust substrate may be added later, or barrier layers may be formed asneeded. The carrier fluid 12 is heat or light hardenable by energyemitted from a curing source 28 to lock the microcapsules 10 in place.Alternatively, the carrier fluid 12 can be a plastic material capable ofbeing injection molded, or a multi-part mixture such as an epoxy, aconductive powder and a hardener.

FIG. 18 illustrates the formation of OLED microcapsule chains formed onan electrode layer. Conductive pixels can be etched into optomagnetic oroptoelectric coating to improve resolution. Or the location of the pixelthat is energized can be controlled by light or laser pulse or othermechanism. The light curable polymer can be cured to a desired depth tocapture the microcapsules 10 that have been attracted, and thus lock in,for example, a microcapsule chain having a desired length.

FIG. 19 illustrates the formation of OLED microcapsule chains formedbetween top and bottom electrode layers. The electrodes 14 can be formedin previous fabrication steps, and may be attracted by a mechanism otherthan the mechanism that orients the OLED particulate.

FIG. 20 illustrates the formation of OLED microcapsule chains within acured carrier 12 for forming a corrosion and/or contamination barrier.The substrate 24 upon which the microcapsules 10 are printed may be amulti-layered composition of polymer, cured monomer, ceramic and fiber,such as glass, creating a durable, flexible substrate 24 that is also abarrier to corrosion for the OLED (as is the microcapsule shell and thecured carrier fluid 12). The conductors 26 that make up the pixelelectrodes 14 can also be used to apply the aligning field used tofabricate the OLED microcapsule structure.

FIG. 21 illustrates a full color display formed in accordance with theinventive OLED device fabrication method. Depending on the quality ofthe barrier created by the inventive fabrication method, there may be noneed for additional barrier layers 30 other than substrates 24 sincecured carrier 12 and microcapsule shells protect the OLED material fromwater vapor and oxygen. Alternatively, additional barrier layers 30,including monomer, polymer, ceramic, fiber, desiccant, getter, scavengerand/or thin metal layers can be included in the structure as needed toprotect the OLED material from contamination. Each color layer can bebuilt on the previous, by a fabrication station. The conductors 26 thatmake up the pixel electrodes 14 can also be used to fabricate the OLEDmicrocapsule structure. In this case, the substrate 24 and pixelelectrode grid become integral parts of the completed OLED device. Theelectric field created by applying voltage to the electrodes 14 can beused to align the OLED microcapsules 10 in chains as shown elsewhereherein. The mechanism for this alignment is similar to the phenomenonthat causes electro-rheological particulate to form chains within acarrier fluid 12. In this case, the OLED microcapsule 10 or the OLEDparticle itself includes the appropriate material component that enablesthe rheological or phoretic effect (i.e., the movement of the OLEDparticulate within the carrier). In addition, or alternatively, magneticmaterial can be used with a magnetic field being applied as the aligningfield. The light emitted from the OLED material when energized by theapplied driving voltage can be used to cure the monomer surrounding themicrocapsules 10. Thus, the voltage applied to the electrodes 14 duringdevice fabrication can be utilized to form the pixel orientation andsimultaneously cure the barrier material.

FIGS. 22-27 illustrate the steps for forming an OLED device inaccordance with an embodiment of the present invention. FIG. 22illustrates step one of an embodiment of the inventive OLED devicefabrication method. Step One: Provide Top and Bottom FlexibleSubstrates. Step Two: Form Barrier layers 30 on Top and Bottom FlexibleSubstrates 24 (FIG. 23). Step Three: Form Top and Bottom Electrodes 14on Barrier layer 30 (FIG. 24). Step Four: Fill Void between Top andBottom Electrode 14 with OLED microcapsules 10 dispersed in uncuredcarrier fluid 12 (FIG. 25). Step Five: Apply potential to electrodes 14to organize OLED microcapsules and/or particulate 10 into chains (FIG.26). Step Six: Cure carrier 12 to lock OLED microcapsule chains betweenthe electrodes 14 to form pixels (FIG. 27). The composition of the OLEDparticulate can be selected so that the characteristics of the OLEDparticulate includes an electro or magneto rheological or phoreticcharacteristic. This rheological or phoretic characteristic is effectivefor causing the OLED particulate to orient and/or migrate in an appliedaligning field.

FIG. 28 shows a magnetically reactive OLED microcapsule 10 for forming acapacitor OLED microcapsule 10 with the aligning field from an aligningfield source 32 turned off. An OLED microcapsule 10 is formed having acapacitor capability.

An OLED material internal phase is encapsulated within a first shell. Anelectrolyte surrounds the first shell and a second shell encapsulatesthe first shell and the electrolyte. The OLED material internal phaseincludes a field reactive material. The field reactive materialcomprises at least one of a magnetically reactive material and anelectrically reactive material effective to orient the OLED microcapsule10 within an aligning field applied from the aligning field source 32.By this construction, OLED material and field attractive material, suchas magnetic material, are microencapsulated within an electricallyconductive shell, forming an OLED/Mag internal core. The OLED/Maginternal core is microencapsulated along with a mixture of electrolyteand light curable monomer liquid phase within a second electricallyconductive shell. The microcapsule shell material is selected to havethe appropriate breakdown voltage at which charge conduction occurs. Themicrocapsules 10 act as capacitor elements that are, for example,charged up with a charging voltage. A trigger voltage is then appliedwhen the OLED pixel is to emit light.

FIGS. 28-30 illustrate the formation of an OLED/Capacitor microcapsule.OLED material and field attractive material, such as magnetic material,are microencapsulated within an electrically conductive shell, formingan OLED/Mag core. The OLED/Mag core is microencapsulated along with amixture of electrolyte and light curable monomer liquid phase within asecond electrically conductive shell. The microcapsule shell material isselected to have the appropriate breakdown voltage at which chargeconduction occurs. FIG. 29 shows a magnetically reactive OLEDmicrocapsule 10 for forming a capacitor OLED microcapsule 10 with themagnetic aligning field turned on with uncured electrolyte mixture. FIG.30 shows a magnetically reactive OLED microcapsule 10 for forming acapacitor OLED microcapsule 10 with the magnetic aligning field turnedon with cured electrolyte mixture. In accordance with this compositionof the OLED microcapsule, the internal phase comprises OLED material anda magnetically reactive material disposed within a first shell. Anelectrolyte and a curable fluid material surround the first shell. Asecond shell encapsulates the first shell, the electrolyte and thecurable material. In response to an applied magnetic field, the positionof the first shell is changeable relative to the second shell. Uponcuring the curable material, the position of the first shell relative tothe second shell is locked in place. This microcapsule 10 structure canbe used to form capacitors/OLED microcapsules 10 which may beparticularly effective for use in passive matrix displays. Typically, apassive matrix display is driven with a relatively high driving energyso that the emission of light by a driven pixel is intense. Thisintensity overcomes the short driving time of the pixel (as comparedwith the more controllable active matrix backplane). This passive matrixdriving scheme results in shorter display life, higher power consumptionand lower display quality. When a charging voltage is applied (such asduring a charging scan of a passive matrix OLED display grid), thecapacitor elements of the microcapsule 10 store applied electricalenergy. The charging voltage can be controllably applied to selectedpixels and in multiple scans to vary the stored charge in themicrocapsules 10 associated with each pixel. When a trigger voltage isapplied (during the display writing scan), the OLED material emits lightin response to the trigger voltage and in a manner dependent on thestored charge. With the proper selection of microcapsule 10 materials,an RC circuit is formed giving the OLED pixel an increased and morecontrolled light emission time and intensity.

FIG. 31 shows a pixel comprised of a chain of capacitor OLEDmicrocapsules being charged by a charging voltage. FIG. 32 shows a pixelcomprised of a chain of capacitor OLED microcapsules being triggered forlight emission by a trigger voltage. The microcapsules 10 act ascapacitor elements that are charged up with a charging voltage. Atrigger voltage is then applied when the OLED pixel is to emit light.Alternatively, the charging voltage may just result in the emission oflight, but the RC circuit nature of the OLED microcapsule creates alonger light emission pulse than the voltage charging pulse, resultingin a higher quality passive matrix displayed image.

FIG. 33 shows OLED microcapsules 10 randomly dispersed within a fluidbut hardenable carrier fluid 12. A first electrode 14 and a secondelectrode 14 are provided defining a gap there between. Within the gap,field reactive OLED particulate is randomly dispersed within a fluidcarrier 12. The electrodes 14 can be preformed on a substrate, such asglass. Alternatively, one or both grids of electrodes 14 can bepreformed on a flexible carrier 12 enabling roll-to-roll manufacturing.The inventive fabrication technology overcomes the last hurdles towidespread commercialization of OLED devices. In the first step of theinventive fabrication method, a mixture of randomly dispersed OLEDparticulate in a fluid conductive carrier is disposed between a grid ofx and y electrodes. The electrodes are pre-patterned on a top and bottomsubstrate (shown, for example, in FIGS. 13, 107 and 108). The substratesare a flexible polymer. Because of the barrier qualities of the carrier,elaborate encapsulation layers are not required.

FIG. 34 shows OLED microcapsule chains aligned within an appliedaligning field formed within unhardened carrier fluid 12. Uponapplication of an aligning field, the OLED field-reactive materialorient along the field lines and form chains within the still-fluidcarrier 12 (analogous to electro rheological fluid mechanics). The nextstep is to apply an aligning field selectively to the volume between thex- and y-electrodes.

The randomly dispersed particulate orient and migrate under theinfluence of the aligning field to form pixels of aligned OLEDparticulate.

Preferably, the spaces between the pixels are devoid of any particulate.The composition of the carrier and the particulate are selected so thatthe preferred path of electrical conductivity is through the alignedparticulate. This structure makes most efficient use of the OLEDmaterial and eliminates cross talk between the display pixels.

FIG. 35 shows OLED microcapsule chains aligned within an appliedaligning field held in alignment within hardened carrier 12. With thealigning field still applied, the carrier 12 is cured (for example,using light or heat) to form a solid phase to lock the chains of OLEDfield-reactive material into position. With the proper selection ofcarrier 12 material, the OLEDs can be energized to create the curinglight to simplify the fabrication process. Alternatively, a light source28 such as a laser or other light emitter, can be used to controllablyapply the curing light. The aligning field maintains the position of theparticulate while the carrier is cured. The carrier changes from a fluidmonomer to a hardened cross-linked polymer by applying ultravioletlight. The formation and preservation of ultra-thin layers of organicmaterial is not necessary. The gap between the x- and y-electrodes ismuch wider, so many of the problems of the current state-of-the-art OLEDfabrication methods are avoided. The resulting display structure isflexible, solid-state and highly robust.

FIG. 36 shows the OLED microcapsule 10 structure shown in FIG. 35 with adrive voltage applied and light being emitted from the OLED microcapsulechains.

When a voltage is applied to the electrodes 14, the OLED chain enableshole and electron movement, raising the energy state of the OLEDmaterial and generating light. The completed display consists of pointsources of light emission (aligned particulate) in a solid-stateprotective matrix (hardened carrier). The resulting device structure isimpervious to water and oxygen. The much wider gap between theelectrodes greatly reduces the problem of dust and particlecontamination. If a short between the electrodes does occur, thestructure is self-healing by automatically disconnecting the shortwithout losing a pixel. During fabrication, pixel electrode alignmentoccurs automatically and precisely. Extremely high resolution, fullcolor, large-sized video displays are obtainable. Cross talk betweenpixels is eliminated, and there is no need for any elaborate deviceencapsulation. The inventive fabrication process is readily adaptable toroll-to-roll processing on flexible plastic substrates using theadaptation of well-established polymer film fabrication methods.

FIG. 37 illustrates a method for forming an OLED particulate having ahole transport layer and an electron transport layer. Hole transportmaterial and electron transport material are combined to form stableparticles. FIG. 37 illustrates the formation of an OLED particle. Holetransport material having a net positive charge and electron transportmaterial having a net negative charge are mixed together in a liquid sothat the opposing polarities of the particles creates an attractiveforce resulting in electrically stable particles. The OLED particulateis formed by providing a first particle, comprised of a hole transportmaterial that has a net positive electrical charge. A second particle isprovided comprised of an electron transport material having a netnegative electrical charge. The hole transport particle and the electrontransport particle are brought together in a liquid and combined to forma unified OLED particulate having a hole transport layer and an electrontransport layer forming a heterojunction between them.

FIG. 38 illustrates a method for forming an encapsulated OLEDparticulate. The hole transport material and the electron transportmaterial can be combined into a single particle by ejecting theconstituent particles towards each other. The positive and negativecharges will attract to form an electrically neutral bipolar particle.This particle may be coated with an encapsulating shell or leftuncoated.

FIGS. 39-41 show the steps for forming a multi-layered OLED particle. Inthis case, as shown in FIG. 39, individual particles of electrontransport material are imparted with a net negative electrical charge bya charge source 34 and ejected from a nozzle 36. Particles of a blockingmaterial are imparted with a net positive charge and ejected from asecond nozzle 36 towards the stream of electron transport materialparticles. Field applying electrodes 38 may be provided for directingthe respective charged particles so that they combine together to forman electrically neutral dual layer particle. The field applyingelectrodes 38 may also be useful for attracting and removing from thecombined particle stream the charged particles that do not combine inthe dual layer particle. In a similar manner, a dual layer holetransport and photo active layer particles can be ejected with inducedcharges and directed to combine into a dual layer particle containingthe hole transport material and the photo active material. As shown inFIG. 41, the two dual layer particles are imparted with oppositeelectrical charge and ejected from nozzle 36 towards each other wherethey combine to form the completed multi layered OLED particulate. Theamount of charge induced in the particles can be controlled to adjustthe alignment of attracted constituents. The number of layers and theirorder can also be controlled as needed.

The OLED particulate comprises layered organic particles, which includea hole transport layer and an electron emitter layer. A heterojunctionis formed at the interface between the hole transport layer and theelectron emitter layer. Each layered organic particle may also include ablocking layer adjacent to the electron emitter layer and an emissivelayer adjacent to the hole transport layer, thereby forming a stackedorganic layered structure. The blocking layer is provided forfacilitating the proper flow of electrons and hole, and the emissivelayer is provided for facilitating the emission of photons when theenergy state of the OLED particulate is raised.

FIG. 40 illustrates a second step in forming a multi-layered OLEDparticulate. The amount of charge induced in particles can be controlledto adjust alignment of attracted constituents. FIG. 41 illustrates athird step in forming a multi-layered OLED particulate. Relatively weakattractive field keeps layered particles properly aligned, withoutcausing attachment of particles to electrodes 14. The relatively morenegatively attractive ETL side attracted to a positive attractive force.More positive towards one end, with an overall net positive charge onHTL/EML layered particle and more negative towards another end, with anoverall net negative charge on ETL/BL layered particle. With the properselection of constituent materials, the electrical properties of the HTLand ETL material should be effective to cause the larger degree ofinduced charge to occur at the ends of the layered particles.

The OLED particulate may comprise a bipolar OLED microcapsule. The OLEDparticulate is formed by the steps of first providing a first particlecomprised of a hole transport material. The hole transport material hasa net first electrical charge. A second particle comprised of anelectron transport material is provided having a net second electricalcharge. The first electrical charge is of opposite polarity from thesecond electrical charge. The first particle and the second particle arebrought together to form a unified OLED particulate having a holetransport layer and an electron transport layer forming a heterojunctionbetween them. The first particle may further include a photon-activelayer. This photon-active layer may be a light emissive layer in whichcase the OLED forms a light emitting device, or a light receptive layer,in which case the OLED forms a light-detecting device.

FIG. 42 schematically shows a full-color OLED display, constructed inaccordance with the present invention, having a dichromatic displaylayer for improving the display contrast, power efficiency and forproviding display viewing in bright sunlight. The dichromatic displaylayer may be formed, for example, using a conventional LCD pixilatedlight modulator layer. Further, the dichromatic display layer can becomprised of dichromatic microcapsules that can be oriented to reflector absorb impinging light using an aligning field. The microcapsules 40can be electrophoretic and oriented using an applied electrical field.In this case, the electrophoretic microcapsules 40 are electricallyreactive. Alternatively, in accordance with the present invention, thedichromatic microcapsules may be magnetically reactive. In this case,the microcapsule can be constructed having a north magnetic pole and asouth magnetic pole, each pole being associated with a respective colorof a bi-color microcapsule (e.g., reflective/absorbtive). A constructionsimilar to the capacitor/OLED microcapsule shown in FIGS. 28-32 can beused to create microcapsules that can be controllably oriented in anapplied magnetic field. The dichromatic display layer provides a lightreflective display for use in bright sunlight and other appropriateambient light conditions, as well as other display enhancing effects.The dichromatic pixel layer can be formed adjacent to the lastsubsequent OLED pixel layer. This dichromatic pixel layer results in adisplay that can be viewed in direct bright sunlight as well as withimproved contrast in indoor ambient lighting conditions. Further,additional subsequent OLED pixel layers can be provided which emit lightin additional color range having a color and/or light intensitydifferent from the color and/or light intensity of the other OLED pixellayers.

To control the reflection of the emitted light from the OLED RGB pixelsin automatic mode the OLED brightness and the reflection/absorptiondichromatic microcapsule 40 is automatically controlled to optimizepower consumption and display quality. Photodetection elements are usedto determine the level of ambient light and adjust thereflection/absorption/image displaying capabilities of the inventivedisplay. Further, the inventive OLED device can be configured so as todetect light impinging on a pixel grid formed in accordance with thepresent invention. In this case, the OLED particulate of a first OLEDpixel layer emits electrical energy in response to the reception ofphotons and applies the electrical energy as a detectable signal to thefirst and second layer electrodes 14. Further, a black and white and/orfull color CCD-type camera can be formed, by tuning the wavelength rangeat which subsequent layers of OLED pixels are photo reactive.Photodetectors are used to determine when to use dichromatic displayelements. If the dichromatic pixels (e.g., dichromatic microcapsules 40)are turned to the reflection side, OLED emission will be reflected andmore light emitted from the display. If turned to the absorption side,better display contrast may be obtained. If the OLED layers are turnedoff, the dichromatic pixels become a reflective (or two color) displayfor use in bright light or energy saving conditions. This driving schemerequires very low power—only have to apply power to the pixels to changeorientation, then the state remains until power is applied again. Forapplications such as cell phones, the ability to see a display in brightlight is an important consideration. When the phone is in brightsunlight, the dichromatic display elements are used and the OLEDs areoff and transparent (the display is reflective and can monochrome (e.g.,a black and white display) or full color). When the phone is indoors orin lower ambient light, the emissive pixels are used (full colordisplay). As examples of how the dichromatic display layer improves theinventive display, under normal ambient light (indoor, office lighting)the dichromatic microcapsules 40 can be oriented to absorb thereflection of ambient light to improve the contrast of the display.

In low ambient light (airplane, car, dusk) the dichromatic displayelements can be turned oriented to reflect the OLED emission so that theOLED display elements can be driven with lower energy consumption. Thedichromatic display elements can be automatically oriented andcontrolled to provide power savings and improve contrast. Light filtersand side/side pixels can be mixed with the display stack to create avariety of display options. Further, IR and other emitters and detectorscan also be included to create “invisible” maps that can only be readwith night vision aides. Other display possibilities include windshieldsthat automatically block out high light sources like the sun andoncoming high beams; and goggles that enhance vision, provide nightvision, and include telescopic and stereoscopic capabilities.

FIG. 43 schematically shows the full-color OLED display shown in FIG.42, with the dichromatic pixels oriented for reflecting emitted OLEDlight. When the dichromatic picture elements are reflective (oriented sothat the reflective side of the sphere is facing toward the emissiveside of the display), then the light emitted from the OLED elements isreflected for use in forming the display image. The orientation of thedichromatic picture elements can be automatically controlled dependingon the ambient light detected by a photodetector.

FIG. 44 schematically shows the full-color OLED display shown in FIG.42, showing the relative strength of reflected light depending on thedichromatic pixel orientations. The orientation of each respective pixelstack's dichromatic pixel element, determines the contrast, ambient andemitted light reflectivity.

FIG. 45 shows magnetically-active OLED microcapsules 10 randomlydispersed within a fluid but hardenable carrier fluid 12 along withdesiccant particulate. The carrier fluid 12 can include a conductiveelement, carbon or powdered iron for example. The carrier fluid 12should be selected to have the appropriate electrical properties so thatthe path of least electrical resistance in the completed display deviceis through the OLED material, and not through the carrier 12.Accordingly, the carrier fluid 12 may have a semi-conductivecomposition. Desiccant and/or scavenger particles 42 are included withinthe carrier fluid 12 to improve protection against contamination. Thedesiccant can be for example, a finely powdered silica basedparticulate, and specific oxygen scavenger material can also be includedto further enhance the protection of the OLAM and other constituents.Examples of the oxygen scavenger material include dimethylpropanolamine,diethylaminoethanol, cyclohexylamine, n-n-diethylhydroxylamine (DEHA),2-amino-2-methyl-1-prop-anol, other amines, or other suitable materialcomposition. The specific scavenger material is selected depending onthe other components in the device to optimize its effectiveness, takinginto consideration factors such as the device optical, electrical andmechanical characteristics. This desiccant/scavenger can be included inthe shell and/or the internal phase of the OLAM microcapsules, dependingon the microcapsule composition.

FIG. 46 shows the magnetically-active OLED microcapsule chains alignedwithin an applied magnetic aligning field within the unhardened carrierfluid 12. The applied magnetic field can be obtained by permanentmagnets brought into position relative to the display electrodes, orelectromagnets that are controlled to apply the magnetic field as neededto cause the desired microcapsule alignment and orientation.

FIG. 47 shows the magnetically-active OLED microcapsule chains alignedwithin the applied magnetic aligning field held in position within thehardened carrier 12. The carrier fluid 12 can include a conductiveelement—carbon, for example. Desiccant (water and/or oxygen scavenger)particles 42 are included within the carrier fluid 12 to improveprotection against contamination.

FIG. 48 shows the magnetically-active OLED microcapsule structure withlight being emitted from the OLED microcapsule chains in response to adriving voltage applied to the electrodes. FIG. 49 schematicallyillustrates a full color OLED display having high intensity visiblelight display layers and an infrared display layer.

FIG. 50 shows an OLED display layer and a liquid crystal lightmodulating layer 44. The liquid crystal light modulating layer 44 can beused as the dichromatic display layer described above. The liquidcrystal light modulating layer 44 can also provide the inventive displaywith the capability of being selectively reflective. With thiscapability, the light-blocking windshield described with regard to FIGS.57 and 58 is obtained. Further, a window can be formed that istransparent when needed, can be switched to being an emissive display(viewable from both or only one side), is selectively light blocking,and can be a bi-color or reflective display.

FIG. 51 shows an inventive OLED display fabricated with thin films oforganic material with photodetection elements. Photodetector elementscan be incorporated into each pixel stack, or disposed in a differentresolution grid. The ambient light, whether sunlight, lamplight orfirelight, received by the photodetectors is used to control the opticalcharacteristics of the OLED pixels associated with each photodetector.This construction can be used with microcapsule-based fabrication or anyother display constructions. This enables features such as windshieldsthat block out (using, for example, LCD-type shutters) high lightsources, such as bright sunshine, overhead streetlights, or headlightsbeaming from another car. OLED solar cell components or pixel layers canbe used to “recycle” the energy emitted by the OLED emitters. Some ofthe emitted light energy impinges on the solar cells and generate light.This, along with the inventions described herein and the sheet batterydescribed in the above-referenced co-owned patent application Ser. No.10/234,301, filed Sep. 4, 2002 entitled “Printer and Method forManufacturing Electronic Circuits and Displays”, can enable lightweight,relatively inexpensive, dichromatic newspapers (as described herein inFIG. 1) that recharge in sunlight (or even indoor ambient light) toenable full-color emissive video or still images.

FIG. 52 shows an OLED microcapsule 10 wherein the shell is slightly lessconductive than the encapsulated OLED material. The shell is slightlymore resistive than the OLED material so that current does not flowaround the shell, but instead flows through OLED material. Theparticulate can be organic or inorganic, with chips of LED materialcombined and oriented, as necessary, with other materials as isdescribed herein with regard to OLAM materials.

FIG. 53 shows an OLED microcapsule 10 wherein the OLED material isencapsulated along with an electrolyte. A hole transport materialcomprises the shell, and a shell around MAG is insulative to keep themagnetic material from having unwanted influence of the electricalbehavior of microcapsule. OLED material is contained within theelectrolyte solution, the electron carriers in the electrolyte can becontrolled depending on the needed specification of the microcapsules10. For example, the microcapsules 10 charge-carrying requirements ofthe electrolyte can be tailored to match the electrical flow for aparticular OLED constituent material. Thus, microcapsules 10 can beformulated based on the empirically or otherwise determinedcharacteristics of a particular formula, or even a particular batch, ofOLAM. Other additional material can be included in the internal phase orthe shell of the microcapsule, or added to the carrier material, orincluded as other microcapsules 10 within the carrier 12. For example, aphosphorescent OLED microcapsule 10 may require different light-inducingapplied electrical energy. Light of a particular wavelength, for exampleinfrared, can trigger the OLED emission at other wavelengths. In thiscase, OLAM, or other material such an inorganic semiconductor, isincluded to generate electricity in response to IR light. The generatedelectricity is used to cause an emission of other wavelengths of lightby the OLED pixel layers. Alternatively, the other wavelengths of lightcan be generated by particles having florescent or phosphorescentphenomenon. This capability makes possible a map, for example, that canbe read with an infrared flashlight (keeping the stealth advantage,while avoiding the need for the map reader to have night vision, as isthe case when the map is the IR emitter).

FIG. 54 shows an OLED microcapsule 10 wherein the OLED material and thehole transport material are contained in solution within a conductiveshell. This construction may be driven with AC or DC current. The OLEDparticulate is formed by microencapsulating an internal phase within ashell. The internal phase or the shell includes an OLED material andeither the internal phase or the shell includes a field reactivematerial. The field reactive material comprises either or both anelectrostatic and a magnetically reactive material. In accordance withanother composition of the inventive microcapsule, the internal phasecomprises an OLED emitter material and an OLED hole transport materialdispersed in solution. Color dyes may also be included within theinternal phase. The solvent may be a fluid organic solvent. In order toprovide the alignment capabilities of the microcapsules 10, either theinternal phase or the shell may include a field reactive component.

FIG. 55 shows the OLED microcapsules 10 shown in FIG. 54 including amagnetically active material. The magnetic material is included as aseparate microcapsule 10 with an electrically insulative shell containedwithin the internal phase of a second conductive shell that alsoencapsulates a solution of the OLED material (electron transportmaterial and hole transport material). The electrically insulatedmagnetic material enables microcapsule alignment within a magneticfield, without it becoming an electrical short within the microcapsule.The OLED microcapsules 10 can have constituent parts including at leastone of hole transport material, electron transport material, fieldreactive material, solvent material, color material, shell formingmaterial, barrier material, desiccant material, scavenger material,colorant material, light curable, heat expandable, heat contracting,heat curable and heat meltable material. The constituent parts of themicrocapsule 10 form at least one internal phase and at least one shell.The constituent parts are selected so as to have electricalcharacteristics that result in a preferred path of electrical conduction(or electron and hole mobility) through the hole transport material andthe electron transport material. By this construction, the microcapsule10 behaves as a pn junction upon application of an electrical potentialto the first electrode 14 and the second electrode 14.

FIG. 56 illustrates the OLED microcapsule 10 shown in FIG. 54 used forcreating a general lighting or display back lighting OLED device. Forgeneral lighting purposes, OLED and hole transport material can bemicroencapsulated in solvent form. The microcapsules 10 are randomlydispersed within a conductive carrier 12 material, for example aconductive epoxy mixture. The microcapsules 10 can be disposed betweentwo planer electrodes 14. The “self-healing” capabilities describedherein are used to correct electrical shorts between the planarelectrodes 14.

FIG. 57 illustrates a transparent, flexible OLED display fabricated foruse as part of a vehicle windshield. A liquid crystal (or other)light-modulating grid may also be included. The light-modulating grid isused to provide a shutter for blocking a high intensity light source 28,such as the sun or oncoming headlights. Photodetector elements (whichmay be included in grid form within the windshield and/or in anotherarrangement such as an array) detects when a light source 28 is at ahigher intensity than the ambient light. At the location of the detectedhigh intensity light source 28, the light is shuttered (e.g., liquidcrystal within certain pixels is oriented so that the incoming light isblocked). A radar system, IR camera of other object detecting system canbe used to determine when an object is in the road, such as a deer,pedestrian, or a dog. If such an object is detected, its image of thatobject or some indication is produced in the OLED display at thelocation on the windshield corresponding to where the object would beviewed by the driver. Information, such as speed, radio channel,incoming cell phone call number, etc., can be displayed by the OLEDdisplay as a heads up display image. For an example of a driver circuitfor the light shutter, a photoactive grid generates an electricalpotential between two electrodes 14. That electrical potential(amplified if necessary) is effective to cause structures (molecules orcrystals or molecular chains) to orient so that light is selectivelyblocked. This mechanism may also be used to create a fresnel-type lenssystem (creating a curvature (focus ability) of a received light imageusing an essentially flat optical element.

FIG. 58 is a block diagram showing the basic components of a driverdisplay system using an OLED display. A controller controls a displaygrid and receives input from a photodetector grid. A display driverdrives the display grid, under the control of the controller, inresponse to the photodetector grid, an IR camera and/or other detectionsystem such as a radar, sonar, ultrasonic, or the like.

FIG. 59 illustrates an OLED light emissive element. The OLED element canbe constructed from sheets of OLED organic material stacks 46, and canbe formed on glass or plastic substrates 24 and cut to size. Theelectrode leads can be fixed to the cut OLED stack 46 and disposedwithin an evacuated or inert gas filled bulb. The bulb can be solid andtransparent or light diffusive, forming a robust, solid state, lightbulb for flashlights or other applications where a conventional LED mayotherwise be employed.

FIG. 60 shows the OLED light emissive element having a conventionallight bulb form factor. OLED light can be fabricated into the same formfactor as a conventional light bulb so that it can be easily installedinto existing light sockets. The orientation of the organic stack 46,reflective electrode and transparent electrode enables the light to beprojected outward from the bulb. An array of devices can be configuredso that the light is emitted in an omni-directional or directionalmanner. The OLED element can be constructed from sheets of OLED lightstacks 46, and can be formed on glass or plastic substrates 24 and cutto size. The electrode leads can be fixed to the cut light stack anddisposed within an evacuated or inert gas filled bulb. The threadedportion of the bulb can include an ac to dc converting circuit so thatthe conventional sockets, lampshades, etc., already in the home oroffice are still usable. Alternatively, another form factor, such asholiday lighting, rope lighting, etc., can be used. The cut OLED lightstack can be shaped as desired, square, long and thin, etc. Also, thesame basic structure can be used to make OLED light in a conventionalLED package.

FIG. 61 illustrates an OLED device fabricated using light emissivelayers and light detecting layers. The OLED display device can includelayers of light emission pixels and layers of light detection pixels.The light detection pixels can be used to detect ambient light andcontrol the intensity of the light emission pixels. As with some of theother device constructions described herein, the formation of the OLEDpixel layers can be done using the inventive microcapsule fabricationmethod and/or a combination with other fabrication methods such asinkjet, spin coating, vacuum deposition, evaporation, etc. for formingan OLED organic stack 46.

FIG. 62 illustrates stereoscopic goggles having OLED display deviceelements 48. The photodetection pixels can be formed so as to effect acamera incorporated within the OLED display device elements 48. Thecamera optics can include lenses that change shape and/or focal pointdepending on whether the image is focusing on the human eye or thecamera pixel elements. Alternatively, or in addition, CCD-type cameras50 can be provided adjacent to the OLED display device elements 48.

FIG. 63 illustrates a flexible OLED display having a curvature thatcompensates for the human eye's range of motion. The image displayed onthe curved wraparound OLED display is refreshed so that the eye movementas well as the head movement of the user is accounted for. With thisstereoscopic vision aide, the user's head movement can be determined byaccelerometers and gyroscopic circuits. The eye movement is determinedby reflecting IR (or some wavelength depending on the ambient light) offthe retina and detecting the reflection by photodetectors which may beincorporated in or adjacent to the OLED display.

FIG. 64 illustrates a flexible OLED display having microlens elements 52for focusing emitted light at the appropriate physical location within ahuman eye. An optical lens can be used to focus light onto CCD-typeelements to create microlens elements 52 that focus the pixel lightsource 54 at the focus spot in the human eye. The optical properties ofthe microlens element 52 can compensate for vision problems.

FIG. 65 illustrates a wraparound visor 56 having a curved, flexible OLEDdisplay and speakers 58. The inventive stereoscopic vision aid has ahigh resolution OLED display. The OLED display is shaped so that fieldof vision is as full as practical.

FIG. 66( a) illustrates a wall 60 of a house having an inventive OLEDdisplay window 62, the window 62 being driven so as to be transparentwith trees 64 outside the house visible through the window 62. Theinventive window 62 can be constructed along the lines of the OLEDdisplays described herein. As with all of the applications for theinventive OLED technology, the various elements comprising the variousversions of the invention described herein can be mixed and matcheddepending on the intended use for a particular OLED display or device.Thus, in this case, the inventive window 62 can be driven so that it istransparent when needed, can be switched to being an emissive display(viewable from both or only one side), is selectively light blocking,and can be a full color, multi-color, monochrome or reflective display.

FIG. 66( b) illustrates the wall 60 of a house having the inventive OLEDdisplay window 62, the window 62 being driven so as to display multiplesimultaneous video streams 66 including videophone communication,Internet web page and a television program. Multiple streams of displayinformation 66 can be simultaneously received and displayed. Forexample, broadcast video content such as a television program may beshown at a first portion of the display, personalized video content,such as a videophone conversation may be shown at a second portion and aweb page, including mapped hyperlink content, may be shown at a thirdportion. With an LCD light modulating layer, the content displayed onthe inventive OLED display window 62 can be viewable from outside thehouse (from poolside, for example), or LCD light modulating layer can becontrolled so that the emitted display light can be blocked from viewfrom outside the house.

FIG. 66( c) illustrates the wall 60 of a house having the inventive OLEDdisplay window 62, the window being driven so as to be a mirror. In thiscase, the LCD light modulating layer can be controlled to block lightfrom being transmitted through the window. Further, as shown in FIG. 57,relatively high intensity light (such as from sun beaming onto thewindow) can be selectively blocked to prevent glare within the house andto keep the house cooler in the summer.

FIG. 67( a) illustrates the use of an inventive flexible large formatdisplay as part of a camouflage system for a vehicle, such as a militarytank. In accordance with this aspect of the present invention, acamouflage system is provided that includes a video camera system thatcaptures a field of view in a direction away from the object to becamouflaged, such as a military tank. On the opposite side of the tankrelative to the field of view, a flexible large format display is usedto display to an external viewer the captured image of the field ofview. FIG. 67( b) illustrates the camouflage system shown in FIG. 67( a)wherein the display area has a curved viewing area. As shown in FIG. 67(b), the effect of displaying the captured field of view on the flexibledisplay is to create the illusion for the external viewer that enablesthe military tank to effectively disappear into the background scene.

FIG. 67( c) illustrates the use of an inventive flexible clothingdisplay as part of a camouflage system for a person. As described above,a camera system captures a field of view. This captured image isdisplayed on the clothing of the wearer so that an illusion is createdthat the wearer disappears into the background scene.

FIG. 67( d) shows the inventive clothing camouflage system shown in FIG.67( b) in use. The clothing may be fabricated in the manner describedherein.

FIG. 68( a) shows the use of flexible, lightweight solar panels as asunlight-to-energy system for powering an aircraft, such as a militaryobservation drone. FIG. 68( b) is a block diagram illustrating somesystem elements of the military observation drone shown in FIG. 68( a).The flexible, lightweight solar panels fabricated in accordance with thepresent invention enable an aircraft, such as an observation drone, tocontinuously fly while being propelled, for example, by a propellerdriven by an electric motor. The electric motor and other onboardelectrical systems receive power directly from the solar panels, or froma battery that is recharged by the solar panels.

FIG. 69 illustrates an embodiment of the inventive light active deviceshowing a semiconductor particulate randomly dispersed within aconductive carrier. A light active device includes a semiconductorparticulate dispersed within a carrier material.

The carrier material may be conductive, insulative or semiconductive andallows charges to move through it to the semiconductor particulate. Thecharges of opposite polarity moving into the semiconductive materialcombine to form charge carrier pairs. The charge carrier pairs decaywith the emission of photons, so that light radiation is emitted fromthe semiconductor material. Alternatively, the semiconductor materialand other components of the inventive light active device may beselected so that light received in the semiconductor particulategenerates a flow of electrons. In this case, the light active deviceacts as a light sensor.

A first contact layer or first electrode is provided so that onapplication of an electric field charge carriers having a polarity areinjected into the semiconductor particulate through the conductivecarrier material. A second contact layer or second electrode is providedso that on application of the electric field to the second contact layercharge carriers having an opposite polarity are injected into thesemiconductor particulate through the conductive carrier material. Toform a display device, the first contact layer and the second contactlayer can be arranged to form an array of pixel electrodes. Each pixelincludes a portion of the semiconductor particulate dispersed within theconductive carrier material. Each pixel is selectively addressable byapplying a driving voltage to the appropriate first contact electrodeand the second contact electrode.

The semiconductor particulate comprises at least one of an organic andan inorganic semiconductor. The semiconductor particulate can be, forexample, a doped inorganic particle, such as the emissive component of aconventional LED. The semiconductor particulate can be, for anotherexample, an organic light emitting diode particle. The semiconductorparticulate may also comprise a combination of organic and inorganicmaterials to impart characteristics such as voltage control emission,aligning field attractiveness, emission color, emission efficiency, andthe like.

The electrodes can be made from any suitable conductive materialincluding electrode materials that may be metals, degeneratesemiconductors, and conducting polymers. Examples of such materialsinclude a wide variety of conducting materials including, but notlimited to, indium-tin-oxide (“ITO”), metals such as gold, aluminum,calcium, silver, copper, indium and magnesium, alloys such asmagnesium-silver, conducting fibers such as carbon fibers, andhighly-conducting organic polymers such as highly-conducting dopedpolyaniline, highly-conducting doped polypyrrole, or polyaniline salt(such as PAN-CSA) or other pyridyl nitrogen-containing polymer, such aspolypyridylvinylene. Other examples may include materials that wouldallow the devices to be constructed as hybrid devices through the use ofsemiconductive materials, such as n-doped silicon, n-doped polyacetyleneor n-doped polyparaphenylene.

In accordance with another aspect of the present invention, a photonreceptive light active device is provided. A first electrode and asecond electrode are provided disposed adjacent defining a gap therebetween. A light active mixture is provided comprised of a carriermaterial and a photon receptive particulate for receiving a photon oflight and converting the photon of light into electrical energy. Thelight active mixture being disposed within the gap between the firstelectrode and the second electrode so that when light energy is receivedby the photon receptive particulate, electrical energy is produced thatcan be derived from an electrical connection with the first electrodeand the second electrode. With this composition and construction, alight-to-energy device is obtained from which a solar cell,photodetector or camera element can be made.

The photon receptive particulate may include at least one of an organicphoton receiver; an inorganic photon receiver, hole transport material,blocker material, electron transport material, and performance enhancingmaterials. The carrier can include at least one of an organic photonreceiver; an inorganic photon receiver, hole transport material, blockermaterial, electron transport material, and performance enhancingmaterials. Further, additional layers may be formed within the gapbetween the first electrode and the second electrode. These additionallayers help to define the mechanical, electrical and opticalcharacteristics of the inventive device. The additional layers mayinclude at least one of an organic photon receiver, an inorganic photonreceiver, hole transport material, blocker material, electron transportmaterial, and performance enhancing materials (e.g., the characteristiccontrolling additives).

As shown in FIG. 70, an embodiment of the inventive light active devicemay have the semiconductor particulate aligned between electrodes. Theemissive particulate acts as point light sources within the carriermaterial when holes and electrons are injected and recombine formingexcitons. The excitons decay with the emission of radiation, such aslight energy. In accordance with the present invention, the emissiveparticulate can be automatically aligned so that a significant majorityof the point light sources are properly oriented and disposed betweenthe electrodes (or array of electrodes in a display). This maximizes thelight output from the device, greatly reduces cross-talk between pixels,and creates a protected emissive structure within the water, oxygen andcontamination boundary provided by the cured carrier material.

In this case, the mixture disposed within the gap between the top andbottom electrodes includes a field reactive OLED particulate that israndomly dispersed within a fluid carrier. An aligning field is appliedbetween the top electrode and the bottom electrode. The field reactiveOLED particulate move within the carrier material under the influence ofthe aligning field. Depending on the particulate composition, carriermaterial and aligning field, the OLED particulates form chains betweenthe electrodes (similar to the particulate in an electrical or magneticrheological fluid in an electric or magnetic field), or otherwisebecomes oriented in the aligning field. The aligning field is applied toform a desired orientation of the field reactive OLED particulate withinthe fluid carrier. The fluid carrier comprises a hardenable material. Itcan be organic or inorganic. While the desired orientation of the fieldreactive OLED particulate is maintained by the aligning field, thecarrier is cured to form a hardened support structure within which islocked in position the aligned OLED particulate.

FIG. 71 illustrates an embodiment of the inventive light active deviceshowing semiconductor particulate and other performance enhancingparticulate randomly dispersed within the conductive carrier material.The semiconductor particulate may comprise an organic light activeparticulate that includes at least one conjugated polymer. Theconjugated polymers having a sufficiently low concentration of extrinsiccharge carriers. An electric field applied between the first and secondcontact layers causes holes and electrons to be injected into thesemiconductor particulate through the conductive carrier material. Forexample, the second contact layer becomes positive relative to the firstcontact layer and charge carriers of opposite polarity are injected intothe semiconductor particulate. The opposite polarity charge carrierscombine to form in the conjugated polymer charge carrier pairs orexcitons, which emit radiation in the form of light energy.

Depending on the desired mechanical, chemical, electrical and opticalcharacteristics of the light active device, the conductive carriermaterial can be a binder material with one or more characteristiccontrolling additives. For example, the binder material may be across-linkable monomer, or an epoxy, or other material into which thesemiconductor particulate can be dispersed. The characteristiccontrolling additives may be in a particulate and/or a fluid statewithin the binder. The characteristic controlling additives may include,for example, a desiccant, a scavenger, a conductive phase, asemiconductive phase, an insulative phase, a mechanical strengthenhancing phase, an adhesive enhancing phase, a hole injecting material,an electron injecting material, a low work metal, a blocking material,and an emission enhancing material. A particulate, such an ITOparticulate, or a conductive metal, semiconductor, doped inorganic,doped organic, conjugated polymer, or the like can be added to controlthe conductivity and other electrical, mechanical and opticalcharacteristics. Color absorbing dyes can be included to control theoutput color from the device. Florescent and phosphorescent componentscan be incorporated. Reflective material or diffusive material can beincluded to enhance the absorption of received light (in the case, forexample, of a display or photodetector) or enhance the emitted lightqualities. In the case of a solar collector, the random dispersalorientation of the particulate may be preferred because it will enable asolar cell to have light receiving particulate that are randomlyoriented and the cell can receive light from the sun efficiently as itpasses over head. The orientation of the particulate may also becontrolled in a solar cell to provide a bias for preferred direction ofcapture light.

The characteristic controlling additives may also include materials thatact as heat sinks to improve the thermal stability of the OLEDmaterials. The low work metal additives can be used so that moreefficient materials can be used as the electrodes. The characteristiccontrolling additives can also be used to improve the mobility of thecarriers in the organic materials and help improve the light efficiencyof the light-emitting device.

FIG. 72 illustrates an embodiment of the inventive light active deviceshowing different species of organic light active particulate dispersedwithin a carrier material. The turn-on voltage for each species can bedifferent in polarity and/or magnitude. Emissions of differentwavelengths or colors can be obtained from a single layer of the mixtureof the organic light active particulate and carrier material. The color,duration and intensity of the emission is thus dependent on thecontrolled application of an electric field to the electrodes. Thisstructure has significant advantages over other full color or multicolorlight devices, and can also be configured as a wide spectrumphotodetector for applications such as cameras. The organic light activeparticulate can include organic and inorganic particle constituentsincluding at least one of hole transport material, organic emitters,electron transport material, magnetic and electrostatic material,insulators, semiconductors, conductors, and the like. As is describedherein, a multi-layered organic light active particulate can be formedso that its optical, chemical, mechanical and electrical properties arecontrolled by the various particle constituents.

FIG. 73 illustrates an organic light active particle formed from apolymer blend and FIG. 74 illustrates the polymer blend organic lightactive particulate dispersed within a conductive carrier. The organiclight active particulate may include particles comprised from a polymerblend, including at least one organic emitter blended with at least oneof a hole transport material, an electron transport material and ablocking material. The polymer blend may be comprised of emitters thatrespond to different turn-on voltages to effect a multicolor device. Thepolymer blend particulate can be dispersed within a carrier thatincludes at least one of the hole transport, electron transport, holeblocker, or other OLED constituent. The carrier may also include otherperformance enhancing materials, such as lithium, calcium, low workmetals, charge injection facilitators, light-to-light emitters (similarto the coating on a florescent light tube) to obtain the desired lightemission. As described elsewhere herein, other particulate and carrieradditives can be incorporated to enhance the characteristics of the OLEDdevice. FIG. 75 illustrates the polymer blend organic light activeparticle showing light active sites. Upon the application of electricalfield to the electrodes, sites within the polymer blend particle willact as point sources of light emissions. These light active sights arelocated where the appropriate constituents of the polymer blend meet sothat electrons and holes injected into the semiconductor materialcombine into excitons and decay with the release of photons. The organiclight active particulate may include microcapsules having a polymershell encapsulating an internal phase. The internal phase and/or theshell can be comprised of the polymer blend including an organic emitterblended with at least one of a hole transport material, an electrontransport material and a blocking material. As with the otherconstructions of the inventive OLAM devices and material compositions,depending on the material compositions and the device structure, thispolymer blend can be used to emit radiation of different wavelengths andcan also be used for light-to-energy devices, such as solar cell andphotodetectors. These structures and compositions can also be used forbio-sensors and other organic light active applications.

One way to make the polymer blend particulate is to precipitate out theparticles from a solution comprised of the OLED constituents in a commonsolvent. Applicant has experimentally formed a polymer blend particulatefrom the constituents Poly[2-Methoxy-5-(2′-ethylhexyloxy)-1,4--phenylenevinylene]; N,N-Di-(napthalen-a-yl)-N,N-diphenyl-benzidine; and2,9-Dimethyl-4,7-diphenyl-1,1-phenanthroline. These OLED materials wereobtained from H. W., Sands Corp, Jupiter, Fla. The three OLEDconstituents were first dissolved in a common solvent, chloroform, andthen a non-solvent was added to form a precipitant of the blendedpolymers.

Nanoparticles are used in applications, such as drug deliver devices.Others have shown that very small polymer-based particles can be made bya variety of methods.

These nanoparticles vary in size, typically from 10 to 1000 nm. A drugcan be dissolved, entrapped, encapsulated or attached to a nanoparticlematrix. Depending on the method of preparation, nanoparticles,nanospheres or nanocapsules can be obtained. (see, BiodegradablePolymeric Nanoparticles as Drug Delivery Devices, K. S., Soppimath etal., Journal of Controlled Release, 70 (2001) 1-20, incorporated byreference herein). In accordance with the present invention, an OLEDparticulate can be formed having a very small particle size. The smallparticle size offers a number of advantages. For example, the ultimateresolution available of a display may be dependent on the sizelimitation of the OLED particles. Thus OLED nanoparticles utilized inaccordance with the inventive fabrication methods will enable extremelyhigh resolution display devices. Also, the very small OLED particle sizewill enable more light point sources within a given volume, such as thevolume making up a display pixel. A large number of light point sourcescan result in more uniform pixel characteristics, longer devicelifetimes and more efficient power consumption. In accordance with thepresent invention, various methods can be employed to form the OLEDnanoparticles. The various methods disclosed in this reference for theformation of drug delivery nanoparticles can be adapted for theformation of OLED nanoparticles. These methods include the solventevaporation method, spontaneous emulsification, solvent diffusionmethod, salting out/emulsification-diffusion method, production of OLEDnanoparticles using supercritical fluid technology, the polymerizationof monomers, and nanoparticles prepared from hydrophilic polymers.

FIG. 76 illustrates a polymer blend organic light active particulatehaving a field attractive constituent for aligning the particle in analigning field. In this case, the particulate includes a field reactivematerial, such as a magnetically reactive speck.

The magnetically reactive speck can be included in the particulatethrough an appropriate encapsulation, mixing, blending or coatingtechnique.

FIG. 77 illustrates composite microcapsules containing multi-layeredorganic light active particles, each having a different light wavelengthemission and turn-on voltage. The composite microcapsules or differentspecies of particulate can be used to form a single layer voltagecontrolled light active device for emitting two or more colors of light.Instead of needing a separate set of electrodes and a separate layer ofthe semiconductor and carrier material mixture, the present inventionenables a single layered device with a single pair of electrodes tocontrollably emit two or more colors of light.

FIG. 78 illustrates another composite microcapsule containingmulti-layered organic light active particles, at least one having afield attractive constituent. The field attractive constituent may berequired to enable alignment of the particles between the drivingelectrodes. When an aligning field is applied, the field reactive OLEDparticulate moves within the carrier material under the influence of thealigning field. The aligning field is applied to form a desiredorientation of the field reactive OLED particulate within the fluidcarrier.

FIG. 79 illustrates three light emitting microcapsule species, eachspecies having a turn-on voltage controlled by the internal phasecomposition and the encapsulating shell composition. The shell may beformed of a polymer having a conductivity based on thickness and/orcomposition so that the specific turn-on voltage of the encapsulatedconjugated polymer particulate is of a desired magnitude. By thisadditional turn-on voltage control enabled by the shell/internal phaseelectrical characteristics, the photons emitted by each species ofconjugated polymer in response to an applied voltage can be tailored asrequired. The carrier fluid can be formulated so that it is more of aninsulator prior to curing, and has the proper degree of conductivityafter curing. In this case, the carrier fluid can act, more or less,like the oil in an oil/particulate electrical rheological fluid. Thehigh voltage required to align the particulate between the electrodescan be applied without too much current passing through the particulateand burning them out. Once aligned, the electrical field can be reducedor eliminated as the carrier fluid cures. The carrier fluid can alsohave additives that affect the turn-on voltages of the different emitterspecies so that the appropriate number of photons is emitted from eachpoint light source for each applied turn-on voltage.

FIG. 80 illustrates an embodiment of the inventive voltage controlledlight active device showing the composite microcapsule particulaterandomly dispersed within a carrier. The internal phase may be a polymerblend containing two or more conjugated polymers, each with a specificturn-on voltage for the controlled emission of color light. In anembodiment of a voltage controlled multi-colored light emitting device,a first electrode is provided with a second electrode disposed adjacentto it and defining a gap there-between. A mixture of an organic lightactive particulate and a conductive carrier material is disposed withinsaid gap. The organic light active particulate is comprised of firstemitting particles including a first electroluminescent conjugatedpolymer. The first emitting particles emit a number of photons of afirst color in response to a first turn-on voltage applied to theelectrodes. The first emitting particles also emit a different number ofphotons, zero or more, of the first color in response to other turn-onvoltages. The organic light active particulate further comprises secondemitting particles including a second conjugated polymer. The secondemitting particles emit a number of photons of a second color inresponse to a second turn-on voltage and a different number of photonsof the second color in response to other turn-on voltages. Thus, in thecase of a multi-colored diode or display, different colors areperceivable by the human eye depending on the applied turn-on voltage.The organic light active layer may also include third emitting particlesincluding a third electroluminescent conjugated polymer. The thirdemitting particles emit a number of photons of a third color and/orintensity in response to a third turn-on voltage applied to theelectrodes and a different number of photons of the third color and/orintensity in response to other turn-on voltages. A full color displaycan be obtained by having the first color red, the second color greenand the third color blue.

The composite microcapsule can contain three OLED particles ormicrocapsules, or it may be made from conjugated polymers and othermaterial, such as non-conjugated polymers, organic light activematerials, field attractive materials, inorganic light active material,etc. Each emitter emits light of a specific color range, R, G or B. Eachcolor particle is formulated so that it emits light when a voltage in aspecific voltage range is applied between the electrodes. A plurality ofcomposite microcapsules are dispersed within a carrier fluid. Thecarrier fluid may be a hardenable material, such as an epoxy, resin,curable organic or inorganic material, heat or light curable monomer,and the like.

FIG. 81 illustrates an embodiment of the inventive voltage controlledlight active device showing the composite microcapsule particulatealigned between electrodes. An aligning field applied between the topelectrode and the bottom electrode causes the field reactive OLEDparticulate to move under the influence of the aligning field. Dependingon the particulate composition, carrier material and aligning field, theOLED particulate forms chains between the electrodes (similar to theparticulate in an electrical or magnetic rheological fluid when anelectrical or magnetic field is applied), or otherwise becomes orientedin the aligning field. The aligning field is applied to form a desiredorientation of the field reactive OLED particulate within the fluidcarrier. The fluid carrier may comprise a hardenable material. While thedesired orientation of the field reactive OLED particulate is maintainedby the aligning field, the carrier is cured to form a hardened supportstructure within which is locked in position the aligned OLEDparticulate.

FIG. 82 illustrates the retinal response of the human eye to wavelengthsof light in the visible spectrum. When light enters the eye, it firstpasses through the cornea at the front of the eye and ultimately reachesthe retina at the back of the eye. The retina is the light-sensingstructure of the eye. The retina includes two types of cells, calledrods and cones. Rods are responsible for vision in low light, and conesresponsible for color vision and detail. There are three types of cones,each type responsive primarily to a specific segment of the visualspectrum. The light received by these rod and cone cells sets offcomplex chemical reactions. The chemical that is formed (activatedrhodopsin) creates electrical impulses in the optic nerve. The braininterprets these electrical impulses in the visual cortex. Thecolor-responsive chemicals in the cones are called cone pigments and arevery similar to the chemicals in the rods. There are three kinds ofcolor-sensitive pigments, red-sensitive pigment, green-sensitive pigmentand blue-sensitive pigment.

Each cone cell has one of these pigments so that it is sensitive to thatcolor. The human eye can sense almost any gradation of color when red,green and blue are mixed. Humans are able to perceive color throughoutthe visual spectrum because of the responsiveness of the three types ofcones. Red absorbing cones absorb best at the relatively longwavelengths peaking at 565 nm. Green absorbing cones have a peakabsorption at 535 nm and blue absorbing cones have a peak absorption at440 nm.

The three types of cones are each most responsive to different portions

(R,G,B) of the visible spectrum, but the segment of responsivenessoverlap. Light of a given wavelength (color), for example 500 nm(green), stimulates all three types of cones, but the green-absorbingcones will be stimulated most strongly.

Typically, a full color display has side by side RGB pixels andgenerates three simultaneous emissions of RGB colored light, producing amixture of wavelengths of light. Color is perceived by the eye throughthe simultaneous stimulation of the three types of cones by the colorlight mixture. In accordance with the present invention, a color isobtained by driving a multi-color producing light active device with anemission cycle during which the appropriate number of photons ofdifferent colors are produced in successive bursts of light emissions. Apredominance of photons of a color is produced during a burst ofemission in response to the application of a turn-on voltage. Anotherburst of a predominance of photons of another color is produced inresponse to the application of a different turn-on voltage. A fractionof the emission cycle is determined during which each turn-on voltage isapplied so that an appropriate number of photons for each color isproduced for each burst. The eye perceives the desired color by thesuccessive predominate stimulation of each type of cone cell. Color isobtained by the combination of Xd # of photons of Red+Yd # of photons ofGreen+Zd # of photons of Blue. It may turn out experimentally that otherwavelengths of light can be used to stimulate the vision system toperceive variable colors from the burst emission of photons, in whichcase the number and wavelength of the different colors along theemissive spectrum can be employed.

The shell of each particle may be a controlling effect on the turn-onvoltage of the encapsulated OLED. The composition of the encapsulatedOLED controls the color of the light emitted. The shell thickness andcomposition can be controlled so that the turn-on voltage of eachprimary color particulate is distinct from the turn-on voltage of theothers. For example, each RGB particle can have a specific shellstructure selected so that when a high turn-on voltage is applied, theelectrons move too slowly through the lower voltage shell and/orinternal phase to cause complete or partial turn-on (i.e., reducednumber of emitted photons) of the encapsulated emitter.

Each color emitter can be formulated so that it has a differentthreshold turn-on voltage and/or a different threshold turn-on pulsewidth and/or a different threshold turn-on polarity. As an example,since more electrons and holes move at higher voltage potential, thehigher voltage emitter made to have a lower pulse width would emit thesame number of photons as the lower voltage, longer pulse widthemitters. But, even though the voltage threshold for lower voltageemitters is exceeded when the higher voltage emitter is driven, thepulse width of the higher voltage is too short to turn-on the lowervoltage emitter. As an example, the hole and/or electron transportmaterial can be formulated to slow down the progress of the electronsand holes in the lower voltage material so that even though moreelectrons and holes are injected at the higher voltage, are not able tocross through the material and recombine in the lower voltage emitter(the recombination of the holes and electrons results in a photon).

A variable DC/AC voltage/current source applies electrical energy to theelectrodes. In response to the applied energy, light is emitted from theparticulate through the top electrode. In an AC voltage application,each cycle has a predetermined voltage. With each cycle, a predominantcolor of light (for example, R,G,B) is emitted in response to thepredetermined voltage (or no color is emitted). The color emitteddepends on the turn-on voltage of the R, G or B particles. Dual colorparticles or tri color particles (or 4 colors, including IR, forexample) are obtainable by the various known particulate constructiontechniques and those described herein. The burst emission cycles arefast enough that the eye perceives the desired color of the visiblespectra. For example, rods and cones of the eye are stimulated by thethree primary colors separately but in quick succession so that eachframe of a video, for example, is perceived in full color. Because ofthe very fast turn-on times of the emitting particles, and the burstemission driving scheme, a passive matrix can be used while stillobtaining superior video images. Each individual scan cycle of anelectrode pair can have a large number of burst cycles. With each burstcycle, a particular predominant color is emitted. Thus, in each scancycle, the eye see separate colored light bursts but the cones and rodsare stimulated in such quick succession that a mix of the primary colors(or, if preferable other two or more colors) is perceived by the brainfrom the optic nerve.

By selecting the appropriate formula of the conductive carrier, it canbe a hole transport vehicle and an electron transport vehicle. Theorganic emitter may not have to be a multi-layered particulate, butrather, it may be just particles of pure organic emitter.

Depending on the configuration and composition of the variouscomponents, the inventive voltage controlled light active device can beAC driven, with the first turn-on voltage having a polarity and thesecond turn-on voltage having an opposite polarity. The differentturn-on voltages can be a mix of voltages of different polarities andmagnitudes.

The organic light active layer may also comprise at least one additionalemitting particles containing another electroluminescent conjugatedpolymer. The additional emitting particles emitting a number of photonsin response to a turn-on voltage and a different number of photons inresponse to other turn-on voltages. The photons emitted by theadditional emitting particles can have a color that is within thevisible spectrum. In this case, the additional emitting particles canenhance the visible display capabilities. For example, the intensity ofthe light emitted by one of the primary color emitters may becomediminished because of the emitter service lifetime. Other emittershaving the same color, but different turn-on voltage can be put intoservice to maintain the effectiveness of the total display. The photonsemitted by the emitting particles may also be outside the range of thevisible spectrum. For example, infra-red photons can be controllablyemitted to enable stealth military application of the inventive display.

The voltage controlled organic light active device can be constructed asa display. In this case, the first electrode is part of an x-grid ofelectrodes and the second electrode is part of a y-grid of electrodes.The mixture of the organic light active particulate and the conductivecarrier material in the gap between the first electrode and the secondelectrode make up an emissive component of a pixel of a display device.

As an example of voltage controlled emitter, the first and the secondelectroluminescent conjugated polymers may include a plurality ofmembers selected from the group consisting of polythiophenes,poly(paraphenylenes), and poly(paraphenylene vinylene), at least some ofsaid members having substituents selected from the group consisting ofalkyl, alkoxy, cycloalkyl, cycloalkoxy, fluoroalkyl, alkylphenylene, andalkoxyphenylene vinylene.

An organic light active display device includes a substrate with a firstgrid of driving electrodes formed on the substrate. A second grid ofelectrodes is disposed adjacent to the first grid of electrodes anddefining a gap there-between. A mixture of an organic light activeparticulate and a conductive carrier material is disposed within thegap. The organic light active particulate comprising first particlesincluding a first electroluminescent conjugated polymer having a firstturn-on voltage and second particles including a secondelectroluminescent conjugated polymer having a second turn-on voltagedifferent than the first turn-on voltage. When the first turn-on voltageis applied, a first color is emitted by the first electroluminescentconjugated polymer. Light having a second color is emitted by the secondelectroluminescent conjugated polymer in response to the second turn-onvoltage applied to the first electrode and the second electrode.

FIG. 83 illustrates the inventive primary color burst driving method forproducing a perceived full color image by the rapid and sequentialbursts of primary colored light emission. In accordance with the presentinvention, a method is provided for driving a multi-color light emittingdevice, the multi-color light emitting device capable of emitting two ormore colors in sequence. Each color is emitted in response to arespective different applied turn-on voltage. During an emission cycle,a first turn-on voltage is applied having a duration to the lightemitting device so that a first burst of a predominant number of photonsof a first color are emitted. A second turn-on voltage is then appliedduring the emission cycle having a duration and at least one of amagnitude and a polarity different than a magnitude and polarity of thefirst turn-on voltage. For the second turn-on voltage duration, a secondburst of a predominant number of photons of a second color are emitted.In this way, during the emission cycle the first burst and the secondburst occur in rapid succession. A human eye receiving the first burstand the second burst is stimulated to perceive a color that is differentthan the first color and the second color.

During the emission cycle, a third turn-on voltage can be applied havinga duration and at least one of a magnitude and a polarity different thanthe magnitude and polarity of the other turn-on voltages. A third burstof a predominant number of photons of a third color are emitted. Duringthe emission cycle, the first burst, the second burst and the thirdburst occur in rapid succession and the human eye receiving the burstsis stimulated to perceive a color different than the first color, thesecond color and the third color.

In accordance with the present invention, the first color is in the redportion of the visible spectrum, the second color is in the greenportion of the visible spectrum and the third color is in the blueportion of the visible spectrum. The light-emitting device is controlledso that the number of photons of each color emitted during each burst ofthe emission cycle results in a predetermined color within the visiblespectrum being perceivable by the human eye. Even though there is notthe three simultaneous emissions of R,G,B emitted by a typical fullcolor display, in accordance with the present invention, the successiveburst emission results in the perception of a predetermined color in thevisible spectrum.

FIG. 84 illustrates the inventive retinex burst driving method forproducing a perceived full color image by the rapid and sequentialbursts of colored light emission. In accordance with another aspect ofthe present invention, the intensity, duration and color emitted by themulti-color light emitting device is adjusted according to a retinexdisplay operation. Edwin Land introduced a theory of color vision basedon center/surround retinex (see, An Alternative Technique for theComputation of the Designator in the Retinex Theory of Color Vision,”Proceedings of the National Academy of Science, Volume 83, pp.3078-3080, 1986). Land disclosed his retinex theory in “Color Vision andThe Natural Image,” Proceedings of the National Academy of Science,Volume 45, pp. 115-129, 1959. These retinex concepts are models forhuman color perception. The earlier retinex concepts involved thecomputations based on when color boundaries were crossed in the lightemitted from an image. Land's retinex concept of human vision has acenter/surround spatial computation with a center having 2-4 arc-minutesin diameter and a surround that is an inverse square function with adiameter of about 200-250 times that of the center. Others have shownthat a digital image can be improved utilizing the phenomenon of retinex(see, U.S. Pat. No. 5,991,456 issued to Rahman et al, the disclosure ofwhich is incorporated by reference herein). The inventors of the U.S.Pat. No. 5,991,456 patent used Land's retinex theory and devised amethod of improving a digital image where the image is initiallyrepresented by digital data indexed to represent positions on a display.The digital data is indicative of an intensity value I.sub.i (x,y) foreach position (x,y) in each i-th spectral band. The intensity value foreach position in each i-th spectral band is adjusted to generate anadjusted intensity value for each position in each i-th spectral band inaccordance with an equation based on the total number of unique spectralbands. A surround function is used to improve some aspect of the digitalimage, e.g., dynamic range compression, color constancy, and lightnessrendition. The adjusted intensity value for each position in each i-thspectral band is filtered with a common function. According to theinventors of the U.S. Pat. No. 5,991,456 patent, an improved digitalimage can then be displayed based on the adjusted intensity value foreach i-th spectral band so-filtered for each position.

FIG. 85 illustrates the inventive adjusted color burst driving methodfor producing a perceived full color image by the rapid and sequentialbursts of adjusted colored light emission. The retinex display operationmay include the steps of providing digital data indexed to representpositions on a display. The digital data is indicative of an intensityfor each position in each spectral band. The intensity of each positionin each spectral band is adjusted to generate an adjusted intensityvalue in accordance with a predetermined mathematical equation. Theadjusted intensity value is filtered for each position with a commonfunction. The turn-on voltages are controlled so that the emission ofphotons of each color is based on the adjusted intensity value for eachfiltered spectral for each position.

FIG. 86 is a flow chart showing the steps of the inventive method forforming a multi-layered organic light active material particulate. FIG.87 illustrates a layered organic light active material particulateformed by the commingling of a particle of hole transport material witha particle of emissive layer material. In this example, a first mistcomprises a hole transport material (HT) and carrier, and a second mistcomprises an emission layer material (EL) and carrier. FIG. 88illustrates the inventive method of forming a layered organic lightactive material particulate from a hole transport constituent and anemissive layer constituent. Referring to FIGS. 86-88, a first mixture((HT) and carrier) is formed of a first organic light active componentmaterial and a first carrier fluid (step one). A second mixture ((EL)and carrier) is formed of a second organic light active componentmaterial and a second carrier fluid (step two). A first mist or veryfine droplets is generated of the first mixture in an environment sothat a first particulate of the first organic light active componentmaterial is temporarily suspended in the environment (step three). Asecond mist of the second mixture is generated in the environment sothat a second particulate of the second organic light active componentmaterial is temporarily suspended in the environment (step four). Thefirst particulate and the second particulate are allowed to commingleand attract together in the environment to form a first layered organiclight active material particulate ((HT)(EL)) (step six). The layeredorganic light active particulate has a first layer of the first organiclight active component material and a second layer of the second organiclight active component material.

FIG. 89 illustrates a multi-layered organic light active materialparticulate formed by the commingling of a layered particle of holetransport/emissive layer material with a particle of electron transportmaterial. FIG. 90 illustrates the inventive method of forming amulti-layered organic light active material particulate from a holetransport/emissive layer constituent and an electron transportconstituent. An organic light active material particulate can be formedhaving multiple layers. A third mixture is formed of a third organiclight active component material (ET) and a third carrier fluid. A fourthmixture is formed of the first layered organic light active materialparticulate ((HT)(EL)) and a fourth carrier fluid. A mist of the thirdmixture is generated in the environment so that a third particulate ofthe third organic light active component material is temporarilysuspended. A mist of the fourth mixture is generated so that the firstlayered organic light active material particulate is temporarilysuspended in the environment. The third particulate and the firstlayered organic light active material particulate are allowed tocommingle and attract together in the environment to form a secondlayered organic light active material particulate. This second layeredorganic light active material particulate includes the first organiclight active material particulate and the third organic light activecomponent material. Thus the resulting organic light active materialparticulate has a multi-layered structure that includes all three of theorganic light active component materials arranged in a desired order((HT)(EL)(ET)).

In accordance with the present invention, a multilayered particulatestructure can be obtained for obtaining electrophosphorescent OLEDparticulate. FIG. 91 illustrates a layered organic light active materialparticulate formed by the commingling of a particle of blocking materialwith a particle of electron transport material. FIG. 92 illustrates theinventive method of forming a layered organic light active materialparticulate from a blocking constituent and an electron transportconstituent. FIG. 93 illustrates a layered organic light active materialparticulate formed by the commingling of a particle of emissive layermaterial with a particle of hole transport material. FIG. 94 illustratesthe inventive method of forming a layered organic light active materialparticulate from an emissive layer constituent and a hole transportconstituent. FIG. 95 illustrates a multi-layered organic light activematerial particulate formed by the commingling of a layered particle ofblocking/electron transport material with a layered particle of emissivelayer/hole transport material. FIG. 96 illustrates the inventive methodof forming a multi-layered organic light active material particulatefrom a blocking/electron transport constituent and a holetransport/emissive layer constituent. As shown in FIGS. 89-96, amulti-layered particle can be built up having the constituent partsordered in a desired manner so that the multi-layered particle is aneffective point source light emitter.

Additional layers can be added to the multi-layered structure by forminganother mixture of another organic light active component material andanother carrier fluid and forming yet another mixture of a previouslyformed layered organic light active material particulate and yet anothercarrier fluid. The resulting particles are suspended in the environmentas described above and allowed to commingle and attract together to formthe multi-layered particulate structure.

At least one of the first, second and subsequent organic activecomponent material may comprise at least one of a hole transportmaterial, an emission layer material, an electron transport material,and a blocking material. Other organic active component material caninclude at least one of a magnetic material, an electrostatic material,a desiccant, hole injecting material, and an electron injectingmaterial. Thus, a selection of constituents can be made so that amulti-layered particulate structure can be formed having desiredelectrical, optical, mechanical, field attractive and chemicalproperties. The number of layers and their order and composition can becontrolled depending on the desired particulate attributes.

FIG. 97 illustrates a layered organic light active material particulateformed by the commingling of a particle of field attractive materialwith a particle of electron transport material. FIG. 98 illustrates theinventive method of forming a layered organic light active materialparticulate from a field attractive constituent and an electrontransport constituent. FIG. 99 illustrates a layered organic lightactive material particulate formed by the commingling of a particle ofemissive layer material with a particle of hole transport material. FIG.100 illustrates the inventive method of forming a layered organic lightactive material particulate from an emissive layer constituent and ahole transport constituent. FIG. 101 illustrates a multi-layered organiclight active material particulate formed by the commingling of a layeredparticle of field attractive/electron transport material with a layeredparticle of emissive layer/hole transport material. FIG. 102 illustratesthe inventive method of forming a multi-layered organic light activematerial particulate from a field attractive/electron transportconstituent and a hole transport/emissive layer constituent. As shown inFIGS. 97-102, the point source light emitting particulate can be fieldattractive by the inclusion of a material, such as a magneticallyreactive material, as one of the constituents of the particulate.

At least one of the first and the second and subsequent carrier fluidsmay be a solvent of the organic light active component material, and thesolvent removed by evaporation or otherwise to leave the particulatesuspended in the environment. Alternatively, a precipitation can beobtained by a suitable chemical reaction depending on the componentmaterial and the solvent. The chemical reaction may be caused by theaddition of material to the solution prior to or after forming the mist.The chemical reaction may be caused by the carrier material of theopposing mist, or the precipitating material may be otherwise appliedwhen the solution is in the mist form. The environment can be gaseous,liquid or a vacuum. It may have a flow, such as a flow of inert gas, tocarry away evaporated solvent and/or to more the very fine droplets andthe commingled particulate.

The first, second and subsequent organic light active component materialmay a fine particulate insoluble in the respective first, second andsubsequent carrier fluids. The third and subsequent organic light activeparticulate may be a multi-layered organic light active materialparticulate, which may be formed by the inventive method,microencapsulation, chemical reaction of two or more constituents,electric or magnetic attraction of two or more constituents, or othermeans for forming a multi-layered organic light active materialparticulate. The organic light active material particulate formed inaccordance with the inventive method may also be encapsulated in a shellto impart chemical, magnetic, electrical or optical attributes to theparticulate. For example, in the case of a voltage controlled emitter,the microcapsule shell can be composed of a material selected to preventunwanted photon emission from the internal phase emitter, and/or topromote wanted photon emission from the emitter, depending on theapplied turn-on voltage.

The environment in which the particulate is formed can be an inert gas,reactive gas, a vacuum, a liquid or other suitable medium. For example,it may be advantageous for the environment to include elements thatperform a catalytic function to promote a chemical reaction in orbetween the constituents in the mists. A characteristic enhancingtreatment may be performed on the formed layered organic light activematerial particulate. The treatment may be a temperature treatment, achemical treatment, a light energy treatment to cause, for example,light activated cross-linking, or other characteristic enhancingtreatment to impart desired attributes to the formed particulate.

The constituents that attract and form the particulate may be given acharge to encourage the commingling into the particulate. For example,the first mist may be given a charge have a polarity and the second mistgiven a charge having an opposite polarity. The electrical attraction isthus enhanced between the first organic light active particulate and thesecond organic light active particulate.

FIG. 103 is a cross section of a coated cathode fiber having a blockinglayer formed on the cathode fiber and an electron transport layer formedon the blocking layer.

FIG. 104 is a cross section of a coated anode fiber having a holetransport layer formed on the anode fiber and an emissive layer formedon the hole transport layer.

FIG. 105 illustrates the coated cathode fiber and the coated anode fibertwisted together to form an emissive fiber. In accordance with thisaspect of the invention, a conductive fiber is coated with the organiclight emitting material. A single conductive fiber can be coated withall or any number of the layers of the organic stack, including ablocking layer, electron transport layer, emissive layer, hole transportlayer, etc. A second conductor can then be formed over the organicstack, such as ITO, so that light generated in the organic stack isemitted through the transparent ITO layer. Alternatively, a conductivewire can be coiled around the organic stack to act as the secondconductor. As shown in FIGS. 35 and 36, as another alternative, thecathode and anode fibers can be coated with respective layers of theorganic stack and then, as shown in FIG. 105, twisted together to forman emissive fiber.

FIG. 106 shows a method for coating an electrode fiber with organiclight active device material. The electrode fiber can be spray coated,spin coated, dip coated and/or plated with the appropriate layers of theorganic stack. Alternatively, the electrode fiber can be vacuum coated,evaporation coated, etc. These emissive fibers can be used for makingitems, such as lights, clothing, wall hangings and carpeting that emitlight.

FIG. 107 is a schematic view of a fabrication line utilizing theinventive OLED particulate/conductive carrier mixture. In accordancewith the present invention, traditional polymer film fabricationtechniques can be applied to the formation of a solid state, flexible,high resolution display. These fabrication techniques can also be usedto form other solid state light active devices such as lightingcomponents and solar panels.

An example of the inventive fabrication method in a roll-to-roll processbegins with a supply roll of bottom substrate and a supply roll of topsubstrate. The substrates have preformed on them transparent electrodepatterns. A slot-die coating stage introduces onto the bottom substratea film of a fluid carrier containing randomly dispersed OLEDparticulate. The top substrate is placed over this film. Pressurerollers ensure the proper uniform thickness of the particulate/carriermixture between the substrates. At an aligning stage, an aligning fieldis applied to the OLED particulate. This applied field causes theparticulate to orient and align within the still fluid carrier. With theapplied field maintaining the position of the aligned particulate, thecarrier is hardened at the curing stage. The aligned particulate islocked in position between the top and bottom electrode grids within thenow solid-state carrier. A treatment stage can be provided, asnecessary, to perform a heat or pressure treatment, or other process, onthe completed display before it is rolled up by the take-up reel.

Our fabrication method has the advantage of utilizing existing polymerfilm substrates, and mature roll-to-roll processing technology. Further,our OLED particulate/carrier fluid composition can be used in otherfabrication processes, including screen and lithographic printing,injection molding, and resin casting.

Using the inventive OLED material composition and fabrication method,the problems of OLED display encapsulation are overcome by thecombination of the barrier properties of our cured carrier, desiccantand scavenger protective particulate (if necessary), and the well-knownwater/oxygen polymer film barriers used in other applications, likepharmaceuticals. Delicate organic thin films are replaced by robust OLEDparticulate or microcapsules that are protected within a solid-statematrix. Display contrast is enhanced by selecting the appropriateoptical qualities of the cured carrier, avoiding the need for costlyalternatives such as anti-reflection layers. The inventive fabricationmethod will be extremely fast and material efficient, and will make themanufacture of an inexpensive, thin, lightweight, bright, flexibledisplay a near-term practical reality.

FIG. 108 shows a polymer sheet substrate having printed on it anelectrode pattern. The pre-patterned electrodes can be formed on thesubstrate using a drum printing method, screen printing, spray, offset,inkjet or other suitable printing technique. The electrode may becomprised of a conductive printable ink that include, for example, aconductive polymer in solution. After printing the electrode pattern,the solvent evaporates leaving behind the patterned conductiveelectrode. Electrochemically prepared polythieno[3,4-b]thiophene ishighly transparent and conductive. This material, or other suitableconductive polymer, metal, or other material can be used as theconductive pre-patterned electrode.

One of the biggest challenges to the OLED display industry is fromcontamination by water and oxygen. The materials involved in smallmolecule and polymer OLEDs are vulnerable to contamination by oxygen andwater vapor, which can trigger early failure. This issue is exacerbatedwhen non-glass substrates are used. Since OLEDs offer the promise of abendable display, attempts have been made to use plastic substrates inplace of glass. Elaborate barrier mechanisms have been proposed toencapsulate the OLED device and protect the organic stack from theingress of water and oxygen. Also, externally applied desiccants havebeen used to reduce the contamination. Neither of these solutions isadequate, adding to the cost and complexity of forming an OLED device.In the end, the problems caused by the ingress of water and oxygen tothe organic stack continue to pose serious technical issues. FIG. 111illustrates a prior art OLED device. Very basically, an OLED iscomprised of extremely thin layers of organic material forming anorganic stack. These layers are sandwiched between an anode electrodeand a cathode electrode. When voltage is applied to the electrodes,holes and electrons are injected into the organic stack. The holes andelectrons combine to form unstable excitons. When the excitons decay,light is emitted.

The current state of every available OLED fabrication technologyrequires the formation of very thin films of organic light emittingmaterial. These thin films are formed by a variety of known techniquessuch as vacuum deposition, screen printing, transfer printing and spincoating, or by the re-purposing of existing technology such as ink jetprinting. In any case, the current state of the art has at its core theformation of very thin film layers of organic material. These thin filmsmust be deposited uniformly and precisely. Such thin layers of organicmaterial are susceptible to major problems, such as loss of filmintegrity, particularly when applied to a flexible substrate. FIG. 112illustrates a prior art OLED device wherein a dust spec creates anelectrical short between the electrodes. The extreme thinness of thelayers of organic material between conductors also results in electricalshorts easily forming due to even very small specks of dust or othercontaminants. Because of this limitation, costly cleanroom facilitiesmust be built and maintained using the conventional OLED thin filmfabrication techniques. Currently, inkjet printing has gained ground asa promising fabrication method for making OLED displays. However, thereare some serious disadvantages to the adaptation of inkjet printing toOLED display fabrication. Inkjet printing does not adequately overcomethe problem of material degradation by oxygen and water vapor. FIG. 113illustrates a prior art OLED device wherein the thin organic film stackis degraded by the ingress of oxygen and/or water. Elaborate andexpensive materials and fabrication processes are still required toprovide adequate encapsulation to protect and preserve the thin organicfilms. It is difficult to align display pixel-sized electrodes andinkjet printed OLED material with the accuracy needed to affect ahigh-resolution display.

FIG. 1 illustrates the expanded gap distance between electrodes inaccordance with the present invention. For illustrative purposes, thedifference between the gap distance of the electrodes in a thin filmorganic stack is shown in prior art FIG. 111, as compared with the muchgreater gap distance between the electrodes in accordance with thepresent invention as shown in FIG. 1. In fact, the gap distancedifference can be much greater than even that illustrated, depending onthe composition of the particle/carrier matrix and the applied voltage.A thin film OLED device typically has organic stack layers that aredeposited with a thickness on the order of about 100 nm. Some layers areless, some are more depending on the material, the desired structure andthe thin film forming method. However, in any case all the conventionalmethods for forming thin film OLED devices result in extremely thinamounts of material disposed between electrodes that are spaced veryclose apart. One of the salient points is that the greatly expanded gapdistance between electrodes enabled by the inventive OLED devicestructure translates into many advantages over the thin film OLED devicestructures. Among the advantages are the reduction or elimination ofcross talk between pixels, much greater tolerance for inclusions offoreign particles, the additional of performance enhancing materialsinto the matrix structure, as well as the many mechanical, electricaland optical advantages discussed elsewhere herein and other suchadvantages that are not enumerated. Further, the composition of theparticulate and the carrier can be tailored depending on the desiredOLED characteristics. The particulate can include a mixture or singlecomponent of organic and inorganic emitter(s), hole transport, blocker,electron transport, and performance enhancing materials. Also, thecarrier can include a mixture or single component of organic andinorganic emitter(s), hole transport, blocker, electron transport, andperformance enhancing materials. Additional layers can be formed betweenthe electrodes and the particulate/carrier layer. These additionallayers can include a mixture or single component of organic andinorganic emitter(s), hole transport, blocker, electron transport, andperformance enhancing materials.

Applicants have discovered that the ultra thin film nature of aconventional organic light active device results in many disadvantages.These disadvantages include, but are not limited to, electrical shortscaused by the inclusion of small foreign particles, cross talk amongpixels in a display array, delamination of the thin film, deteriorationof the thin film by the ingress of oxygen and water, and other seriousfailings. In accordance with the present invention, the disadvantagescaused by having an extremely small gap distance between electrodes isovercome by expanding this gap distance. Thus, in accordance with thepresent invention, an organic light active device includes a firstelectrode and a second electrode disposed adjacent to the firstelectrode. The first and second electrode define a gap there between. Anorganic emissive layer is disposed within said gap. To overcome the thinfilm issues, and to enhance the performance of the inventive device, agap expanding composition is also disposed within said gap. This gapexpanding composition is effective to increase the gap distance betweenthe top and bottom electrode.

The gap expanding composition may include at least one of an insulator,a conductor and a semiconductor. The gap expanding composition caninclude at least one additional layer which may be formed between thefirst electrode and the second electrode. The additional layers mayinclude at least one of an organic photon receiver, an inorganic photonreceiver, hole transport material, blocker material, electron transportmaterial, radiation emitting material and performance enhancingmaterials. The gap expanding composition can include at least one of adesiccant; a scavenger, a conductive material, a semiconductivematerial, an insulative material, a mechanical strength enhancingmaterial, an adhesive enhancing material, a hole injecting material, anelectron injecting material, a low work metal, a blocking material, andan emission enhancing material.

The emissive layer can comprise an emissive particulate dispersed withina carrier. The emissive particulate has a first end having an electricalpolarity and a second end having an opposite electrical polarity. Theparticulate can be alignable within the conductive carrier so thatcharge carriers of a first type are more easily injected into the firstend and charge carriers of a second type are more easily injected intothe second end.

The emissive layer may be an organic thin film layer. The gap expandingcomposition can include a conductive, insulative and/or semiconductivematerial composition that reduces the emission efficiency of theemissive layer while increasing the light active device effectiveness byexpanding the gap distance between the electrodes. With a carefulselection of constituent components, this reduction in efficiency can belimited so that the benefits of expanding the gap distance between theelectrodes can be obtained without too much cost in device efficiency.

FIG. 110 illustrates a single layered multi-color pixel in accordancewith the present invention. In accordance with one of the embodiments ofthe present invention, a multicolor OLED device is formed that includesparticulate that is capable of emitting photons corresponding to avisible (or invisible) spectrum of radiation depending on an appliedvoltage or other emission triggering mechanism.

FIG. 114 is a cross sectional schematic view illustrating the extrusionof light active fiber having aligned OLED particulate. FIG. 115 is aperspective schematic view illustrating the extrusion of light activefiber. FIG. 7 is a cross section of a segment of extruded light activefiber. FIG. 117 is a schematic view of the segment of extruded lightactive fiber driven by a voltage applied between electrodes. Theinventive light active fiber includes an elongated hardened conductivecarrier material. A semiconductor particulate is dispersed within theconductive carrier material. As shown in FIG. 117, a first contact areais provided so that on application of an electric field charge carriersof a first type are injected into the semiconductor particulate throughthe conductive carrier material. A second contact layer is provided sothat on application of an electric field to the second contact layercharge carriers of a second type are injected into the semiconductorparticulate through the conductive carrier material. As shown in FIGS.114 and 115, the randomly dispersed particulate within a carrier iscontained within a vessel and may be extruded to form an emissive fiber.The fiber is formed, for example, in a manner similar to the formationof monofilament fishing line. The particulate/carrier mixture exits thevessel through an exit port and, may then be subjected to an aligningfield so that the particulate is aligned prior to the carrier beinghardened. The semiconductor particulate may comprise at least one of anorganic and an inorganic semiconductor. The particulate can include anorganic light active particulate including at least one conjugatedpolymer. The conjugated polymer has a sufficiently low concentration ofextrinsic charge carriers so that on applying an electric field betweenthe first and second contact layers to the semiconductor particulate(through the conductive carrier material) the second contact layerbecomes positive relative to the first contact layer and charge carriersof said first and second types are injected into the semiconductorparticulate. The injected charge carriers combine to form in theconjugated polymer charge carrier pairs which decay radiatively so thatradiation is emitted from the conjugated polymer. The organic lightactive particulate can include particles including at least one of holetransport material, organic emitters, and electron transport material.The organic light active particulate can include particles including apolymer blend. The polymer blend includes an organic emitter blendedwith at least one of a hole transport material, an electron transportmaterial and a blocking material. Depending on the phrasing, the emittercan be considered an electron transport material and/or a blockingmaterial, etc. The salient point being the formation of a particulatethat is capable of photon emission in response to an applied voltage.The organic light active particulate may comprise microcapsulesincluding a polymer shell encapsulating an internal phase. The internalphase may comprise, for example, a polymer blend including an organicemitter blended with at least one of a hole transport material, anelectron transport material and a blocking material. The conductivecarrier material may comprise a binder material with one or morecharacteristic controlling additives. The characteristic controllingadditives are a particulate and/or a fluid and may include a desiccant;a conductive phase, a semiconductive phase, an insulative phase, amechanical strength enhancing phase, an adhesive enhancing phase, a holeinjecting material, an electron injecting material, a low work metal, ablocking material, and an emission enhancing material. For example, alow work function metal particulate can be included as a characteristiccontrolling material within the carrier material and/or as a constituentof the emissive particulate.

The light active fiber can be used, for example, in lighting, light-toenergy devices, displays (as described below) or other uses. Forexample, the fiber can be an active component in a light fiber datatransmission line. A section of the light active fiber which convertslight to energy can be provided for receiving a light signal andconverting it into electrical energy. This electrical energy can beamplified and used as a signal to drive another section of light activefiber which is emissive. In this way, along the pathway of the lightfiber data transmission line, the inventive light active fiber can beused to amplify the signal and improve transmission quality anddistance.

FIG. 118 is a cross sectional schematic view illustrating an extrudedlight active fiber having a conductive electrode core and a transparentelectrode coating. FIG. 119 is a perspective schematic view illustratingthe extrusion of the light active fiber having a conductive electrodecore and a transparent electrode coating. FIG. 120 illustrates anextruded light active fiber having a conductive electrode core and atransparent electrode coating connected with a voltage source. The firstand the second contact may comprise a first conductive member disposedlongitudinally within the elongated hardened conductive carriermaterial. The other of the first and the second contact may comprise asecond conductive member disposed adjacent to the first conductivemember so that at least a portion of the semiconductor particulate isdisposed between the first conductive and the second conductive member.The first conductive member may be a conductive material comprised of atleast one of a metal and a conductive polymer disposed in the interiorof the elongated hardened conductive carrier material; and the secondconductive member comprises a conductive material comprised of at leastone of a metal and a conductive polymer disposed as a coating on theexterior of the elongated hardened conductive carrier material. Further,the composition of the particulate and the carrier can be tailoreddepending on the desired OLED characteristics. The particulate caninclude a mixture or single component of organic and inorganicemitter(s), hole transport, blocker, electron transport, and performanceenhancing materials. Also, the carrier can include a mixture or singlecomponent of organic and inorganic emitter(s), hole transport, blocker,electron transport, and performance enhancing materials. Additionallayers can be formed between the electrodes and the particulate/carrierlayer. These additional layers can include a mixture or single componentof organic and inorganic emitter(s), hole transport, blocker, electrontransport, and performance enhancing materials.

FIG. 121 is a cross sectional schematic view illustrating the extrusionof light active ribbon having aligned OLED particulate. FIG. 122 is aperspective schematic view illustrating the extrusion of light activeribbon. FIG. 123 is a segment of extruded light active ribbon. FIG. 124is a cross-sectional view of the segment of extruded light active ribbonhaving wire electrodes incorporated within the ribbon and driven by avoltage applied between electrodes. The extruded shape and orientationof the aligned particulate can be controlled depending on desiredcharacteristics of the light active fiber.

FIG. 125 illustrates a light active fiber extrusion and choppingmechanism for forming uniform lengths of OLED light active fiber. Inthis case, the extruded fiber can be formed and chopped into uniformlengths. These lengths can be dispersed within a carrier and become theparticulate in the particulate/carrier mixture disclosed herein.

FIG. 126 illustrates OLED light active fiber randomly dispersed betweentwo electrodes. FIG. 127 illustrated the OLED light active fibersaligned between the two electrodes. FIG. 128 illustrates OLED lit activefibers randomly dispersed between two electrodes having a gap distanceclose to the uniform length of the fibers. FIG. 129 illustrates the OLEDlight active fibers aligned between the two electrodes having a gapdistance close to the uniform length of the fibers. As shown elsewhereherein, in accordance with the present invention, emissive particulatedispersed within a carrier can be used to form an organic light activedevice. In accordance with this embodiment, the emissive particulate canbe elongated fiber having the composition described herein. Theadvantages of the elongated particulate can be the formation of lightchannels within the carrier. These light channels may be effective forincreasing the efficiency and/or the display or device qualities.

FIG. 130 illustrates light active fibers woven into carpeting. FIG. 131illustrates a light active cloth weave. The light active fiber describedherein can be spun into thread then woven into yarn. These light activethreads and yarn can be formed into various articles, includingcarpeting, wall hangings, clothing and other like articles.

FIG. 132 illustrates a curved large format surround display formed inaccordance with the present invention by tiling length of displaysections. One of the many advantages of a flexible display is theability to create a wrap around display and provide more completeimmersion within the display content. In accordance with the presentinvention, the length of display that can be fabricated is extremelylong due to the roll-to-roll fabrication processing. By tiling strips ofroll-to-roll fabricated displays together, large format, surrounddisplays can be obtained.

FIG. 133 illustrates a method of forming a two layer ultra-thinmulti-layered OLED fiber by drawing and thinning. FIG. 134 illustrates amethod of forming four layer ultra-thin multi-layered OLED fiber bydrawing and thinning. By pulling the constituent OLED materials intofibers through a die (if necessary) and adjacent to each other amulti-layer thin fiber can be formed. Electrode layers can besimultaneously formed, later coated or otherwise applied, or themulti-layered fiber can be particlized to form the particulate of theinventive particle/carrier mixture. The particalization can include lowtemperature to improve the process. Further, another method for makingthe particles is to form layers of the constituent OLED materials on aslippery surface, such as a teflon surface, or a smooth surface, such asglass, and then scrap the layers and chop the scrapping, as necessaryinto particles or fibers.

FIG. 135 is a cross sectional view showing a wire having an electrontransport coating layer. FIG. 136 is a cross sectional view showing awire having a hole transport coating layer. FIG. 137 illustrates coatedwire intersecting electrodes for forming light emitting pixels at theintersections. By coating appropriate electrode wires, and thenintersecting the coated wires, the OLED layered stack can be obtained atthe wire intersection. These wires can then be driven to form a displayor light.

FIG. 138 illustrates the inventive OLED particulate/conductive carriermixture formulated for being formable into useful products throughplastic molding techniques. The carrier material can be composed so thatit is formable into items using conventional plastic molding techniques,such as injection or vacuum molding. The particulate can be aligned, orremain random, while the carrier is fluid, depending on the desiredcharacteristics of the molded device. In accordance with this aspect ofthe present invention, an injection moldable light active material isprovided comprising: a semiconductor light active particulate dispersedwithin a hardenable carrier material. The semiconductor light activeparticulate may include at least one of an organic and an inorganicsemiconductor. The organic light active particulate can includeparticles including at least one of hole transport material, organicemitter, and electron transport material. The organic light activeparticulate can include particles including a polymer blend. The polymerblend may include an organic emitter blended with at least one of a holetransport material, an electron transport material and a blockingmaterial. Additional organic emitters can be included within the polymerblend. The organic light active particulate can comprise microcapsulesincluding a polymer shell encapsulating an internal phase comprised of apolymer blend.

The carrier material can be a hardenable binder material with one ormore characteristic controlling additives. The characteristiccontrolling additives may include at least one of a particulate and afluid. The characteristic controlling additives may include a desiccant,a scavenger, a conductive phase, a semiconductive phase, an insulativephase, a mechanical strength enhancing phase, an adhesive enhancingphase, a hole injecting material, an electron injecting material, a lowwork metal, a blocking material, and an emission enhancing material. Theparticulate may include at least one of an organic emitter, an inorganicemitter, hole transport material, blocker material, electron transportmaterial, and performance enhancing materials. The carrier may includeat least one of an organic emitter, an inorganic emitter, hole transportmaterial, blocker material, electron transport material, and performanceenhancing materials (e.g., the characteristic controlling additives).

In accordance with the present invention, the injection moldable lightactive material can be provided wherein the semiconductive light activeparticulate is comprised of first emitting particles for emitting anumber of photons of a first color in response to a first turn-onvoltage applied to the electrodes and emitting a different number ofphotons of the first color in response to other turn-on voltages. Thesemiconductive light active particulate may further include secondemitting particles. The second emitting particles emit a number ofphotons of a second color in response to a second turn-on voltage and adifferent number of photons of the second color in response to otherturn-on voltages. By this composition and construction, a multi-coloredlight active material is obtained.

The particulate can be composed so as to have a first end having anelectrical polarity and a second end having an opposite electricalpolarity. The particulate is alignable within the conductive carrier sothat charge carriers of a first type are more easily injected into thefirst end and charge carriers of a second type are more easily injectedinto the second end.

FIG. 139 illustrates an inventive OLED solid state light having aconventional light bulb form factor. Global lighting is currently a 40billion dollar industry world-wide, posting sales of over 12 billion ayear. The U.S. Dept. of Energy predicts that LED's will account for 20%of all illumination by 2010, and slash energy use worldwide 10% by 2025.The inventive OLED solid state light can include a self-containedvoltage converter so that a conventional light bulb form factor can beused, and the OLED solid state light easily substituted for theconvention, inefficient, light bulb.

FIG. 140 illustrates a step of spray painting a reflective conductivelayer of an OLED device. FIG. 141 illustrates a step of spray paintingan emissive layer of an OLED device. FIG. 142 illustrates a step ofspray painting a transparent electrode of an OLED device. A reflectiveelectrode can be applied or sprayed onto a surface to form a firstelectrode. A particulate/carrier mixture can next be sprayed or rolledover the first electrode layer. The carrier can be composed of a solventand material having an adhesive quality so that the mixture acts like aconventional spray paint. A second electrode can be formed over theparticulate/carrier mixture. Appropriate contact lands and insulativecomponents are also applied to drive the electrodes so that the lightactive particulate emits radiation, and/or converts light to energy.

FIG. 143 illustrates a step in an inventive method for making a lightactive device showing a light active mixture disposed between an x and yelectrode grid. In accordance with another aspect of the presentinvention, a method is provided for making a light active device. Amixture is provided containing a monomer and light active material. Thelight active material contains at least one of an energy-to-lightmaterial for emitting light in response to an applied electrical energyand a radiation-to-energy material and generating electrical energy inresponse to irradiation.

In accordance with the present invention, a light active device ismanufactured using a self-assembly technique. Light active material isprovided in a first region. A polymer is provided in a second region.The polymer is formed by selectively cross-linking a monomer from amixture containing the monomer and the light active material. Theselective cross-linking causes a concentration of the light activematerial at the first region and a concentration of the polymer at thesecond region. A first electrode and a second electrode may be providedhaving the polymer and the light active material disposed there between.

The light active material may be organic light emitting diode materialfor emitting light when a voltage is applied to the first electrode andthe second electrode. The light active material may comprise inorganiclight emitting diode material for emitting light when a voltage isapplied to the first electrode and the second electrode. The lightactive material may comprise a radiation-to-energy material forgenerating an electrical current in response to radiation, depending onthe intended use, the radiation may be in the visible and/or invisiblespectrum.

The light active material may comprise an organic light active materialincluding at least one conjugated polymer. The conjugated polymer havinga sufficiently low concentration of extrinsic charge carriers so that onapplying an electric energy to the light active material charge carriersare injected into the light active material and combine to form in theconjugated polymer charge carrier pairs which decay radiatively so thatradiation is emitted from the conjugated polymer. The light activematerial may comprise an organic and/or an inorganic semiconductor. Thelight active material may comprise organic particles including a polymerblend. The polymer blend can be an organic emitter blended with at leastone of a hole transport material, an electron transport material; ablocking material and a liquid crystal. The light active material can beprovided as nanostructures, and could include molecules synthesizedhaving constituent parts that provide different functionality to thenanostructure. For example, a liquid crystal molecule can providealignment and migration properties, a chromophore molecule can providelight emission properties, and a cross-linkable monomer can provideselective hardening and migration properties.

The light active material may comprise microcapsules including a polymershell encapsulating an internal phase including an organic emitter. Themixture may also include characteristic controlling additives. Thecharacteristic controlling additives may include, for example, adesiccant; a conductive phase, a semiconductive phase, an insulativephase, a mechanical strength enhancing phase, an adhesive enhancingphase, a hole injecting material, an electron injecting material, a lowwork metal, a blocking material, an emission enhancing material and aliquid crystal.

FIG. 144 illustrates another step in the inventive method for making alight active device, showing a polymerization/migration step. Themonomer is selectively cross-linked in a pattern to form a polymer. Asthe cross-linking reaction progresses, the monomer migrates in responseto the selective cross-linking pattern, causing the cross-linked monomer(a polymer) and the light active material to become concentrated inseparate regions. FIG. 145 illustrates another step in the inventivemethod for making a light active device, showing an aligning step. Theend result is a solid polymer with light active regions embedded in apattern corresponding to the selective cross-linking pattern.

FIG. 146 illustrates another step in the inventive method for making alight active device, showing a controlled pixelated light emission. Themixture may be disposed between a first electrode and a secondelectrode, which may form the electrode grid of a pixilated display orlight sensor. The light active material may comprise organic lightemitting diode material for emitting light when a voltage is applied tothe first electrode and the second electrode. The light active materialmay comprise inorganic light emitting diode material for emitting lightwhen a voltage is applied to the first electrode and the secondelectrode. The light active material may comprise a radiation-to-energymaterial for generating an electrical current in response to radiationin the visible spectrum, and/or it may be responsive to radiation in theinvisible spectrum, such as x-ray, ultraviolet or infrared radiation.

FIG. 147 illustrates a step in an inventive method for making a lightactive device, showing a bottom substrate having a bottom electrodepattern formed thereon. In accordance with another aspect of the presentinvention, a method is provided for making a light-emitting device. Theinventive steps include providing a bottom substrate, with a bottomelectrode over the bottom substrate.

FIG. 148 illustrates another step in the inventive method for making alight active device, showing a light active mixture disposed at a lightactive layer over the bottom electrode pattern. An emissive layer isdisposed over the bottom electrode. The emissive layer includes amixture of a dispersed OLED particulate in a monomer fluid carrier. FIG.149 illustrates another step in the inventive method for making a lightactive device, showing the patterning of the light active layer byirradiation through a mask. The monomer is selectively polymerizedcausing the OLED particulate to concentrate in emissive regions and thepolymerized monomer to concentrate in polymerization regions.

FIG. 150 illustrates another step in the inventive method for making alight active device, showing the migration of light active material intolight active regions. The light active material may include at least oneof an organic emitter, an inorganic emitter, hole transport material,blocker material, electron transport material, and performance enhancingmaterials. The particles of the light active material may have a firstend having an electrical polarity and a second end having an oppositeelectrical polarity. The particulate may be alignable within the carrierso that charge carriers of a first type are more easily injected intothe first end and charge carriers of a second type are more easilyinjected into the second end.

FIG. 151 illustrates the composition of constituents in a multi-colorlight active mixture. In accordance with the present invention,energy-to-light, or light-to-energy material can be a constituent of, orbe formulated as, a cross-linkable monomer material. As shown in FIG.151, red, green and blue emissive components can be associated withrespective monomers or hardenable material, each having a specificpolymerization parameter such as a wavelength or radiation, a catalyst,a temperature, or the like.

The light active material may comprise first emitting particles emittinga number of photons of a first color in response to a first turn-onvoltage and emitting a different number of photons of the first color inresponse to other turn-on voltages. The light active material mayfurther comprise second emitting particles. The second emittingparticles emitting a number of photons of a second color in response toa second turn-on voltage, and a different number of photons of thesecond color in response to other turn-on voltages. The light activematerial may further comprise third emitting particles. The thirdemitting particles emitting a number of photons of a third color inresponse to a third turn-on voltage applied to the electrodes and adifferent number of photons of the third color in response to otherturn-on voltages.

As shown in FIGS. 152-155, the inventive method can be used to form afull color light active device. As shown in FIG. 152, the inventivemethod for making a multi-color light active device includes disposing amulti-color light active mixture disposed over a patterned bottomelectrode grid. Red, green and blue emissive components can beassociated with respective monomers or hardenable material, each havinga specific polymerization parameter such as a wavelength or radiation, acatalyst, a temperature, or the like. The emissive components can alsobe associated with a migration assisting material, such as a liquidcrystal.

FIG. 153 illustrates a step in the inventive method for making amulti-color light active device, showing the selective patterning of oneof the color light active regions. In this case, the red emissivecomponents migrate into rows (or into pixels) by the selectivepatterning and polymerization of monomer1 associated with the redemissive component.

FIG. 154 illustrates a step in the inventive method for making amulti-color light active device, showing the patterned color lightactive regions. As shown, when the mixture is irradiated through thepatterned mask, at the bright regions in the pattern, the monomer1undergoes polymerization. As the polymerization reaction progresses,monomer1 and the red component migrates from the dark regions to thebright regions, causing the other components, green and blue, to becomeconcentrated in the dark regions. The end result is a solid polymercontaining the red emissive component formed in the selective pattern.

FIG. 155 illustrates a full-color light active device having red, greenand blue side-by-side patterned color light active regions. Bypatterning and irradiating the mixture in a manner similar to thepatterning of the red component, the green and blue components areformed into rows. A fourth monomer (not shown), having yet anotherpolymerization parameter can also be included which is then polymerizedbetween the emissive rows.

FIG. 156 illustrates a step in an inventive method for making apixilated light active device; showing a mixture of light activematerial disposed over a patterned bottom electrode grid. A mixturecontaining a light active material, such as an emissive particulate (ep)dispersed in a monomer carrier. The monomer may be selectivelypolymerized using a radiation source transmitted through a patternedmask to form light and dark regions corresponding to the polymerizationregions and the emissive regions. FIG. 157 illustrates another step inthe inventive method for making a pixilated light active device, showingselective patterning through a pixel grid mask. The emissive regions canbe formed into individual pixels surrounded by the polymerizationregions. FIG. 158 illustrates another step in the inventive method formaking a pixilated light active device, showing the migration of lightactive material to pixel regions. The patterned mask includes at leastone of the bottom electrode and a top electrode provided over theemissive layer.

FIG. 159 illustrates the composition of constituents in a light activedevice having pixels and conductive pathways formed by a self-assemblyprocess. The light active materials, such as emissive components (ep)can be associated with a monomer or hardenable material, each having aspecific polymerization parameter such as a wavelength or radiation, acatalyst, a temperature, or the like. Or, the light active material canbe associated with a migration facilitating material, such as a liquidcrystal, magnetic, paramagnetic or electrostatic material. A conductivematerial (C) can also be provided. The conductive material can beassociated with another or hardenable material, each having a specificpolymerization parameter such as a wavelength or radiation, a catalyst,a temperature, or the like. Or, the light active material can beassociated with a migration facilitating material, such as a liquidcrystal, magnetic, paramagnetic or electrostatic material.

FIG. 160 illustrates a step in an inventive method for making a lightactive device having pixels and conductive pathways formed by aself-assembly process. A light active mixture is disposed over a bottomelectrode formed on a substrate. FIG. 161 illustrates another step inthe inventive method for making a light active device by self-assembly,showing the selective patterning of the conductive pathways byirradiation through a mask. A non-conductive monomer (not shown) can beselectively patterned into the emissive regions to form conductivepathways between the polymerization regions. The conductive pathways canform an electrode grid of a display device. The mixture can furtherinclude a conductive material capable of being patterned into theconductive pathways. FIG. 162 illustrates another step in the inventivemethod for making a light active device by self-assembly, showing thepatterned conductive pathways. The conductive components ((ep) and (C))patterned into the conductive pathways.

FIG. 163 illustrates another step in the inventive method for making alight active device by self-assembly, showing the selective patterningof pixel regions by irradiation through a mask. The monomer can bepolymerized under a first polymerization condition such as a firstirradiation wavelength, temperature or other polymerization causingparameter. The conductive material can include a second monomer capableof being polymerized under a second polymerization condition, such as asecond irradiation wave-length, temperature or other polymerizationcausing parameter. FIG. 164 illustrates another step in the inventivemethod for making a light active device by self-assembly, showing thepatterned pixel regions and conductive pathways. The emissiveparticulate and the conductive material can be patterned in theconductive pathways by selectively polymerizing the conductive material,causing the emissive particulate to concentrate in emissive pixels andthe conductive material to concentrate in non-emissive regions betweenthe emissive pixels. An aligning field can be applied during thepolymerization step or other time when emissive or light activeparticulate is able to migrate. The aligning field can be magnetic orelectric, and the patterned electrodes can be used to define thealigning fields.

FIG. 165 schematically illustrates a light active device made byself-assembly, showing emissive/more conductive zones, non-emissive/moreconductive zones and non-emissive/less conductive zones. The lightactive particulate can include a liquid crystal constituent and achromophore constituent. A top electrode over the emissive layer, thetop electrode can be patterned into an electrode grid so that the deviceacts as a pixilated display or light sensor. At least one performanceenhancing layer (not shown) can be provided between the bottom substrateand the emissive layer. This performance enhancing layer can include,for example, a light absorbing or reflecting layer, a charge injectioninhibiting or facilitating layer, and/or a barrier layer for preventingthe ingress of, for example, moisture or oxygen. In accordance with theinvention, a light-emitting device can be manufactured usingself-assembly techniques. A bottom substrate is provided and a bottomelectrode provided over the bottom substrate. An emissive layercomprising a mixture including an emissive/more-conductive material anda non-emissive/less-conductive material is disposed over the bottomsubstrate. The mixture is selectively patterned causing theemissive/more-conductive material to concentrate in emissive regions andthe non-emissive/less-conductive material to concentrate in non-emissiveregions.

FIG. 166 illustrates a cubic volume of a randomly dispersed light activematerial in a light polymerizable monomer carrier. A mixture of a lightactive material and a light polymerizable monomer fill a volume. Themixture is irradiated with two or more laser beams. The laser beams arealigned and polarized to generate a specific holographic interferencepattern having alternating dark and light areas. FIG. 167 illustratesthe cubic volume shown in FIG. 166, showing the light active materialand polymerized carrier after holographic patterning using aninterference pattern generated by laser beams. At the bright regions inthe pattern, the monomers undergo polymerization. As the polymerizationreaction progresses, the monomer migrates from the dark regions to thebright regions, causing the light active material to become concentratedin the dark regions. The end result is a solid polymer with droplets ofliquid crystal embedded in a pattern corresponding to the dark regionsof the holographic interference pattern.

Thus, in accordance with the present invention, a laser interferencepattern can be used to selectively pattern the mixture to form a threedimensional arrangement of light and dark regions corresponding to thenon-emissive regions and the emissive regions. The three-dimensionalpattern can be used to selectively pattern the mixture to form a threedimensional structure containing the light active material (ep), and mayalso include other components, such as the conductor material (C) notshown, making a desired pattern of conductive pathways and emissivematerial within the mixture volume. The emissive regions are formed intoindividual pixels surrounded by the non-emissive regions. The mixturecan further comprise a non-emissive/more-conductive material. Theemissive/more-conductive material and the non-emissive/more-conductivematerial can be patterned into conductive pathways between thenon-emissive regions. The emissive/more-conductive material and/or thenon-emissive/more-conductive material can include a liquid crystalconstituent.

With respect to the above description, it is realized that the optimumdimensional relationships for parts of the invention, includingvariations in size, materials, shape, form, function, and manner ofoperation, assembly and use, are deemed readily apparent and obvious toone skilled in the art. All equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described. Accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

1. A method for making a light active device, comprising: providing amixture of light active material and a monomer in a first region and asecond region, wherein said light active material comprises a pluralityof electro-statically active microcapsules each comprising OLED materialencapsulated within a polymer shell; forming chains of saidelectro-statically active microcapsules in said first region; curingsaid monomer to form a polymer in said first region and in said secondregion to lock said chains of said electro-statically activemicrocapsules in said first region.
 2. The method of claim 1, whereinsaid electro-statically active microcapsules are bipolar.
 3. The methodof claim 1, further comprising: providing a first electrode and a secondelectrode and wherein said polymer and said electro-statically activemicrocapsules are disposed between said first electrode and said secondelectrode.
 4. The method of claim 3, wherein said OLED material emitslight when a voltage is applied to said first electrode and said secondelectrode.
 5. The method of claim 1, wherein said OLED material includesat least one conjugated polymer, said at least one conjugated polymerhaving a sufficiently low concentration of extrinsic charge carriers sothat on applying an electric energy to said light active material,charge carriers of first and second types are injected into said OLEDmaterial and combine to form, in said conjugated polymer, charge carrierpairs which decay radiatively so that radiation is emitted from saidconjugated polymer.
 6. The method of claim 1, wherein said chains ofsaid electro-statically active microcapsules are formed by applicationof an electric field to said mixture of said light active material andsaid monomer.
 7. The method of claim 1, further comprising providing afirst electrode and a second electrode having said polymer and saidlight active material disposed therebetween, wherein said chains of saidelectrostatically active microcapsules form pixels between said firstelectrode and said second electrode.
 8. A method for making a lightemitting device, comprising: providing a substrate; providing anelectrode over at least a portion of said substrate; disposing anemissive layer comprising a mixture including a light active materialcomprising a plurality of electrostatically active microcapsules havingOLED material encapsulated within a polymer shell dispersed in a monomerfluid carrier over said substrate; forming chains of saidelectrostatically active microcapsules; and selectively polymerizingsaid monomer to lock said chains of said electrostatically activemicrocapsules in emissive regions and causing said polymerized monomerto concentrate in polymerization regions.
 9. The method of claim 8,wherein said electrostatically active microcapsules are bipolar.
 10. Themethod of claim 8, wherein said chains of said electrostatically activemicrocapsules are formed by application of an electric field to saidmixture of said light active material and said monomer.
 11. The methodof claim 8, further comprising providing a first electrode and a secondelectrode having said polymer and said light active material disposedtherebetween, wherein said chains of said electrostatically activemicrocapsules form pixels between said first electrode and said secondelectrode.
 12. The method of claim 8, further comprising applying analigning field when said electrostatically active microcapsules aremobile; wherein patterned electrodes are used to define said aligningfield.
 13. A method for making a light active device, comprising:providing a mixture containing light active material and a monomer in afirst region and a second region, said light active material comprisinga plurality of electro-statically active microcapsules comprising OLEDmaterial encapsulated within a polymer shell; forming chains of saidelectro-statically active microcapsules in said first region; forming apolymer by selectively cross-linking said monomer; causing migration ofsaid monomer by said selective cross-linking of said monomer; causingsaid chains of said electro-statically active microcapsules to be lockedin said first region; and causing said polymer to be concentrated atsaid second region.
 14. The method of claim 13, wherein saidelectro-statically active microcapsules are bipolar.
 15. The method ofclaim 13, further comprising providing a first electrode and a secondelectrode having said polymer and said light active material disposedbetween said first electrode and said second electrode.
 16. The methodof claim 15, wherein said OLED material emits light when a voltage isapplied to said first electrode and said second electrode.
 17. Themethod of claim 13, wherein said OLED material includes at least oneconjugated polymer, said at least one conjugated polymer having asufficiently low concentration of extrinsic charge carriers so that onapplying an electric energy to said light active material, chargecarriers of first and second types are injected into said OLED materialand combine to form, in said conjugated polymer, charge carrier pairswhich decay radiatively so that radiation is emitted from the conjugatedpolymer.
 18. The method of claim 13, wherein said chains of theelectrostatically active microcapsules are formed by application of anelectric field to said mixture of said light active material and saidmonomer.
 19. The method of claim 13, further comprising providing afirst electrode and a second electrode having said polymer and saidlight active material disposed therebetween, wherein said chains of saidelectrostatically active microcapsules form pixels between said firstelectrode and said second electrode.